Well, how about an update?
I have been picking away at the wiring. Along with doing a few car shows, fixing mowers and pressure washing my 23 yr old deck I haven't put a lot of time into the van this summer. I finished up the front relay center last night. I'll blow this all apart for paint before I get it wired into the van harness.
http://images53.fotki.com/v1520/phot...MVC041F-vi.jpg
This box carries the relays for the three cooling fans, with their respective manual switch relays, the start relay for the rear mounted solenoid and a spare. The add on box on the right is for the adjustable temp sensor for the rad fans.
This is a pic after I got the fuse panel and ground strip mounted. You can see by the relay labels I did some repurposing before i started wiring. I needed two relays for the trans cooler fan so I decided to move the Park Neutral and B/U Light relays inside under the dash.
http://images18.fotki.com/v438/photo...MVC028F-vi.jpg
Here is a back view of the box. All of the wires exit through the back and should be fairly well hidden after I get them mounted and loomed. The 4ga power wire will connect directly to the power distribution block which is fed from the alternator and also connects to the battery for charging. This panel will have power at all times so the fans can run for a short time after the engine is shut off for some residual cooling.
http://images19.fotki.com/v678/photo...MVC038F-vi.jpg
I also have a good start on wiring the rear relay box. This one isn't as busy because I had the room to make it a bit larger and there isn't as much "stuff" going into it.
You can see the general layout here. A 200 amp Maxi-Fuse on the left. 6 position fuse panel in the middle with a barrier strip on the bottom and the relay bridge on the right.
http://images15.fotki.com/v588/photo...3/photo-vi.jpg
The maxi-fuse will pull power off the switched side of the master disconnect and send it too the front through a 4ga cable. This cable will also be the charge wire from the alternator block up front. The fuel pump relay is the only dedicated relay in this box so there is a LOT of room for anything I want to add in the future.
Here is some of the wiring in place. I pulled power to the fuse panel off the fused side of the maxi-fuse.
http://images51.fotki.com/v747/photo...3/photo-vi.jpg
Because I have all of the circuits designed I know how many wires will be coming into and out of the box. I cut short lengths of the required wire sizes to use to establish the snap bushing sizes. I wrote the required drill size beside the hole locations. I used a step drill to drill these holes.
http://images16.fotki.com/v388/photo...3/photo-vi.jpg
That's what I've been doing, how about you?
Mark