DIY Cooling Fan Gizmo - Page 8 - Honda ATV Forum
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post #71 of 174 (permalink) Old 04-23-2019, 08:30 AM
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You're never going to get into this kind of technical wizardry in the fb groups that seem to be the place where the average person seems to go now. I joined a few to see....no thanks. No technical help or experts there, not to mention nowhere to archive or threads to go back to. Everything gets buried. I'm sticking around here.
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2004 TRX400FA (Rancher 400AT)
MotionPro twist throttle kit
12" handlebar mounted light bar
rear rack wheelchair carrier
Cycle Country 48" plow w/ KFI hybrid mount
Champion 3000 lb winch w/ synthetic rope
23" Titan 489's all around (saving clutch)

2011 Grizzly 450 EPS

Others in the family: '04 TRX250TE, '85 TRX250 Utility (X2), '05 TRX90, '06 TRX500FA, '95 TRX400FW,' 88 TRX125
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post #72 of 174 (permalink) Old 04-23-2019, 08:40 AM
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I much prefer the forums for the reasons you just mentioned @wheelsquad.

Unfortunately FB has killed off a lot of forums. Several Jeep forums I used to frequent are gone, and I don't think Highlifter will hold on much longer. Hardly any traffic there anymore, and there is a treasure trove of info there.
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post #73 of 174 (permalink) Old 04-23-2019, 01:18 PM
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Never done the Facebook thing, probably never will.
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post #74 of 174 (permalink) Old 04-25-2019, 01:29 PM Thread Starter
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@wheelsquad

Do you have a KFI inch mount like this one on your Rancher?

https://www.kfiproducts.com/100505-h...nch-mount.html

I am looking for a mounting location for the power supply & relays enclosure on my Rancher frame and decided that my PS/relays box will bolt flush to the underside of my (modified) KFI winch mount directly under and between the four winch motor mounting bolts. It will be protected there on my bike. See the pic...

Another possible option I saw is one of the right side or left side frame tubing supports behind the inner splash guard. Those location should work using two U-bolts/nuts with an aluminum plate for the box to bolt onto.

Whad'ya think?
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post #75 of 174 (permalink) Old 04-25-2019, 02:30 PM
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Quote:
Originally Posted by retro View Post
@wheelsquad

Do you have a KFI inch mount like this one on your Rancher?

https://www.kfiproducts.com/100505-h...nch-mount.html

I am looking for a mounting location for the power supply & relays enclosure on my Rancher frame and decided that my PS/relays box will bolt flush to the underside of my (modified) KFI winch mount directly under and between the four winch motor mounting bolts. It will be protected there on my bike. See the pic...

Another possible option I saw is one of the right side or left side frame tubing supports behind the inner splash guard. Those location should work using two U-bolts/nuts with an aluminum plate for the box to bolt onto.

Whad'ya think?
KFI winch mount?? Oh you know it! I love me some KFI. Great plan.
retro likes this.

2004 TRX400FA (Rancher 400AT)
MotionPro twist throttle kit
12" handlebar mounted light bar
rear rack wheelchair carrier
Cycle Country 48" plow w/ KFI hybrid mount
Champion 3000 lb winch w/ synthetic rope
23" Titan 489's all around (saving clutch)

2011 Grizzly 450 EPS

Others in the family: '04 TRX250TE, '85 TRX250 Utility (X2), '05 TRX90, '06 TRX500FA, '95 TRX400FW,' 88 TRX125
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post #76 of 174 (permalink) Old 04-25-2019, 06:02 PM Thread Starter
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Cool, using the backside of the winch mount will be easy, like taking candy from a baby. :-)

I been tinkerin' this week while waiting on orders to arrive, so I'll show ya whats up so far and talk about stuff I'm scheming on.

First off, after sleeping on my brass frame idea for securing around the rubber buttons in the cover watertight, I decided that the 1/8" thick polycarbonate display lens could be extended, so that the polycarbonate lens does double-duty securing the buttons too. So only one part needs to be fabbed up and that plastic frame should be a lot stronger, and easier to JB-weld flatly into the cover. I think I have some smoke-tinted 1/8" polycarbonate sheet that is new, so I'll be getting started on that this weekend.

The two oil temp sensors are finished.

The two W1209 boards are ready for the polycarbonate lens/buttons fabbed parts. The lower PCB edges of both boards were filed down to match the curvature of the enclosure for slightly offset mounting the boards inside... to provide extra space for gluing/sealing the lens down around the upper curved portion of the enclosure. I also decided to just mount trimpots on those boards in some JB-weld, rather than solder in fixed SMD resistors. There is plenty of extra space for them along the lower edges of the boards and I'd rather calibrate those boards deadnut using trimpots during final assembly, than have to perform those calibrations later on using the correction menu. The menu can be used to finely tune later on, if you have a more accurate meter than my two china rigs are. :-)

The two power supply & relays enclosures are nearly done. Just need those wire spools, 5-pin connectors and two filter capacitors, then it'll be JB-weld and Ultra-black gasket sealer time! The 9 volt regulators' TO-220 packages are soldered down onto homemade brass sheet heatsinks (a pair of scissors guided by a blind man with shaky hands are all thats needed, LOL) then the thin brass sinks were soldered down to the perf boards. We'll only need about 65 milliamps of current max, so those regulators probably don't need to be heatsinked, but I added the brass anyway just to be sure.

As you'll notice in those two PS/Relay boxes pics below I have added a 2nd power supply/relays board to one of them. The 2nd PS board will provide power for my Start-in-any-gear mod on my Rancher. That mod is in the midst of a makeover idea using an LDO 5 volt regulator and two small PCB mount (one 5v, one 12v) relays. There is so much extra space available inside those enclosures, that I decided to include my revamped Start-in-any-gear mod inside for weatherproofing.

If you want one of those mods added to your box @wheelsquad, just hollar an' it'll get done!

More pics coming following the weekend... :-)
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post #77 of 174 (permalink) Old 04-25-2019, 08:25 PM Thread Starter
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Nevermind the Start-in-any-gear mod offer @wheelsquad I forgot that 400ATs already have that feature.


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post #78 of 174 (permalink) Old 04-26-2019, 12:43 AM
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I am thinking about adding a '' home made '' fan kit to this '88 trx300fw project I am working on, I got the mounting brackets already on the frame, so all I need to do is rig up brackets from a fan I have on hand to the frame brackets, my question is, can this gizmo operate the fan through the oil temp ?, if so ?, I might want one of these for this !. but I got to get a fan rigged up on the frame first. found a oem fan on ebay, seller is asking 800 bucks for it !..lol.
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post #79 of 174 (permalink) Old 04-26-2019, 01:56 AM Thread Starter
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Quote:
Originally Posted by shadetree View Post
my question is, can this gizmo operate the fan through the oil temp ?, if so ?, I might want one of these for this !.
Ya, these gizmos monitor/display the current oil temp in the sump and kicks a cooling fan On and Off according to the upper and lower temp thresholds that the driver has chosen. While the fan relay is kicked on the red LED next to the display is lit up and goes off when the fan kicks off.

Settings can be changed on-the-fly anytime and as often as ya wish and all settings are saved in NV memory, so previous settings are still active next time the key is turned on, even if stored without a battery in the bike.

The gizmos also alert the driver (the display reads "LLL") if the oil temp sensor gets unplugged, a wire gets cut or ripped out by a stick in the trail, or if the oil temp sensor fails out of range, etc.

They also alert the driver (display reads "HHH") if the oil overheats.

There are 7 menu settings that can be tailored to suit, plus the driver can raise or lower the fan kick-on temp quickly by just tapping a button and incrementing up or down.

There are menu-definable upper and lower range limit features provided too, so the driver (or a kid playing around with it?) can't accidentally set the fan On/Off temps too high or too low. No need to enter the menus once they've been set up and the gizmo is fast, accurate and very precise... they measure and display oil temp in 0.1 C increments up to 99.9 C (1 C increments between 100-110 C) within a max tolerance of +/- 0.1 C.

Ideally, you'd want an oil cooler mounted in front of a fan. The motor oil performs the majority of cooling in an air-cooled motor... much more important than air flow around the head/cylinder, although air flow helps.

If ya want one of these gizmos @shadetree hollar an' I'll make ya one. But it'll be quite a while before I can get started on any others... I'm way behind schedule on my own stuff now. Spring has sprung and I'm running my butt off catching up. :-)

I'll start a list.. add ya to the top... fair enuff?



Last edited by retro; 04-26-2019 at 01:59 AM.
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post #80 of 174 (permalink) Old 04-26-2019, 03:51 AM Thread Starter
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Once these two gizmos are done I'll need to restock my bins with a gazillion common parts that have been depleted after making the selectable gizmos, making my own (and my neighbors) occasional gadgets/repairs, and now making these fan control gizmos. I am all out of many common parts and hardware bits, so I'm gonna need to make a big list up and order all of those things back in. Plus I'll have to order in more enclosures, more voltage regulators, more relays, more wire, more shrink tubing, more W1209s, more connectors, more polycarbonate... everything that goes into those gizmos gots to be carried in.

So heads up! If any of you regulars want me to make one of these for ya, hollar so you'll be added to the list and so I'll know how many extra parts to buy! I'm not gonna stock completed gizmos... and can only make them (between every spring and winter I'm busy as a bee) as I find some spare time on stormy days in my offgrid shack. An early request and extended patience be much appreciated. :-)
@shadetree yers be next. :-)


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