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Electrical System Implementation Plan - 2006 Land Cruiser

Document Purpose

This file provides a detailed, actionable implementation plan for completing the electrical system installation based on the current state documented in ELECTRICAL_CIRCUITS.md. This plan bridges the gap between "what's installed" and "what's wired and functional."

Last Updated: 2025-12-28 Based on: technical-specs/ELECTRICAL_CIRCUITS.md (Last Updated 2025-12-23) Related: planning/PROJECT_PLAN.md, RFI.md

Current State Assessment

✅ PHYSICALLY INSTALLED (Hardware Present)

  • Primary Battery: Odyssey ODX-AGM31A with SLEE tray (SOK0019)
  • Secondary Battery: Odyssey ODP-AGM35 with SLEE tray + Redarc DC-DC 50A
  • Washer Bottle: Relocated using PLAIDWAGON kit (WT100-0307)
  • SPOD Units: 2x BantamX Touchscreen Universal (BXTSBUNI36) on PowerTray mount
  • Air Compressor: ARB CKMTA12 Twin Motor mounted on 2nd battery tray
  • Winch: COMEUP SOLO 12.5rs with Egis XD Flex 2 controller
  • AirDown Drawer System: SS1-100 Series installed in cargo area

⚠️ PENDING INSTALLATION (Hardware Purchased)

  • Hood Solar Panel: SLEE STF1351 (100W) - needs mounting and wiring to Redarc
  • ARB Pressure Control: ARB 0830001 dash panel - CRITICAL FOR JAN 24 TRIP

🔄 PARTIALLY WIRED (Functional but Incomplete)

  • Second Battery: Connected but charging system needs verification
  • Air Compressor: Mounted and wired to secondary battery (verify trigger circuit)
  • Winch: Installed with power and control (verify all connections)

📋 DOCUMENTED BUT NOT WIRED (Circuits Planned)

  • 24 SPOD Circuits: All circuit assignments documented, none wired yet
  • 8 Fuse Block Circuits: Planned but fuse block not mounted
  • 4 MSD Relay Circuits: Conceptual design only, not implemented
  • Lighting Loads: Rigid Adapt 40", Rigid Ignite Spots, roof floods - hardware exists but no power
  • Interior Circuits: Seat heaters, ambient lights, ham radios - planned but not wired

Critical Information Gaps (See RFI.md for Details)

The following information is REQUIRED before proceeding with installation:

  1. SPOD Mounting Location - Driver side or passenger side? (RFI-101)
  2. Touchscreen Controller Location - Dashboard location not specified (RFI-102)
  3. Circuit Wire Specifications - Gauge, length, color code for each circuit (RFI-103)
  4. Factory Integration Points - Exact wire tap locations for triggers (RFI-104)
  5. Grounding Architecture - Ground point locations and wire sizing (RFI-105)
  6. Solar Panel Installation Plan - Mounting and wiring route to Redarc (RFI-106)
  7. Big 3 Upgrade Specifications - Wire gauge and routing (RFI-107)
  8. Interior SPOD Exact Location - "Behind 2nd row" is vague (RFI-108)
  9. Fuse Block Mounting - Center console vs behind 2nd row? (RFI-109)
  10. Wire Color Coding Standard - Need consistent color scheme (RFI-110)

Implementation Phases

PHASE 0: Pre-Installation Research & Planning (CURRENT)

Status: 🔄 In Progress Completion Target: Before starting Phase 1 Critical Path: Must resolve all RFIs before proceeding

Tasks: - [ ] Resolve all critical RFIs (RFI-101 through RFI-110) - [ ] Document as-installed SPOD locations with photos - [ ] Measure all wire runs and create cut list - [ ] Create wire color coding standard - [ ] Source all required wire, connectors, terminals, heat shrink - [ ] Identify all factory wire tap points (door pins, reverse trigger, etc.) - [ ] Map grounding points in engine bay and interior - [ ] Create detailed installation procedure for each phase

Deliverables: - Completed RFI findings in RFI.md - Wire cut list with gauge, color, length for every circuit - Connector/terminal bill of materials - Factory integration diagram showing tap points - Ground point location map - Updated ELECTRICAL_CIRCUITS.md with as-built details

PHASE 1A: Engine Bay Power Infrastructure (URGENT - Jan 24 Trip)

Status: 🔄 In Progress (Dual battery operational, solar and winch pending) Completion Target: January 15, 2025 Prerequisites: Phase 0 critical RFIs resolved

Scope: Complete engine bay power distribution and charging system

PRIORITY ORDER FOR JAN 24 TRIP: 1. HIGHEST: Winch permanent power installation (RFI-111 blocking) 2. HIGH: ARB Pressure Control panel installation 3. MEDIUM: Solar panel installation (nice to have, not critical) 4. MEDIUM: Big 3 electrical upgrade verification/installation

Tasks: 0. Winch Permanent Power Installation ⚠️ HIGHEST PRIORITY - CRITICAL FOR JAN 24 - Status: Hardware on hand, needs installation - Blocking: RFI-111 (control knob location must be decided) - Must Purchase: 250A circuit breaker (Blue Sea 7186 or Stinger SGP90250) - Installation Steps: - [ ] Purchase 250A circuit breaker (~$35-60) - [ ] Decide Egis control knob location (resolve RFI-111) - [ ] Mount 250A circuit breaker near primary battery (driver side) - [ ] Connect primary battery (+) → 250A breaker (winch-supplied cable or 2 AWG) - [ ] Mount Egis relay pack near battery (behind driver headlight area) - [ ] Connect 250A breaker output → Egis relay power input (2 AWG) - [ ] Connect Egis relay ground to battery (-) or chassis (2 AWG) - [ ] Connect Egis relay to winch motor (6-pin DTM connector) - [ ] Route control wire (18-20 AWG) through firewall to cab - [ ] Mount control knob in cab at selected location - [ ] Connect control wire to knob - [ ] Test winch operation (In/Out/Off) - [ ] Verify no power draw when knob is OFF - [ ] Re-torque all connections after initial testing - See: planning/WINCH_INSTALLATION_CHECKLIST.md for detailed procedure - Safety Note: 250A circuit breaker is NON-NEGOTIABLE safety requirement

  1. Big 3 Electrical Upgrade (RFI-107 must be resolved first)
  2. Status: Unknown if already installed - need confirmation
  3. If not installed:
  4. Install upgraded alternator to primary battery cable
  5. Install primary to secondary battery cable (through Redarc)
  6. Install engine block ground upgrade cable
  7. Test voltage drop across all three connections

  8. Document wire gauges, lengths, and routing

  9. Hood Solar Panel Installation (RFI-106 must be resolved first)

  10. Mount SLEE STF1351 panel on hood
  11. Route solar wiring to Redarc DC-DC charger solar input
  12. Waterproof all connections
  13. Test charging output in sunlight

  14. Apply BoatLIFE Life-Calk sealant to all penetrations (verify RFI-001)

  15. Redarc DC-DC Charger Verification

  16. Verify input from alternator (voltage, current, wire gauge)
  17. Verify solar input connection (if solar installed)
  18. Verify output to secondary battery
  19. Test charging profile (bulk, absorption, float stages)
  20. Set charging parameters per Redarc manual

  21. Label all connections

  22. ARB Pressure Control Installation (CRITICAL - JAN 24 TRIP)

  23. Mount ARB 0830001 panel in dashboard or center console
  24. Wire power from secondary battery (fused circuit)
  25. Connect air pressure sensor line to ARB manifold
  26. Wire compressor trigger relay
  27. Test auto-shutoff at set PSI (test at 30 PSI)
  28. Label control panel and test all functions
  29. Document final installation location with photo

Testing: - [ ] Verify alternator charges primary battery correctly - [ ] Verify Redarc charges secondary battery from alternator - [ ] Verify solar charging (if installed) - [ ] Test ARB compressor activation from pressure control panel - [ ] Verify auto-shutoff at target PSI - [ ] Load test: run compressor to 100 PSI and verify system stability

Deliverables: - Fully functional dual battery charging system - Working hood solar panel (if installed) - Operational ARB pressure control system - Updated ELECTRICAL_CIRCUITS.md with as-built Big 3 specs - Installation photos

PHASE 1B: Critical Lighting for Jan 24 Trip (URGENT)

Status: 📋 Pending (Blocked by RFIs) Completion Target: January 15, 2025 Prerequisites: Phase 0 complete, RFI-101, RFI-102, RFI-103, RFI-104 resolved

Scope: Wire minimum circuits needed for January 24 offroad trip

Critical Circuits (Minimum Viable): 1. Rigid Ignite Spot Pods (Left & Right) - Engine Bay SPOD 1, Circuits 1-2 - 20A breaker per circuit - Manual SPOD switch trigger - Roof penetration through A-pillar (routing TBD per RFI-104)

  1. Winch Relay Control - Engine Bay SPOD 2, Circuit 6
  2. 5A control circuit
  3. Momentary SPOD switch

  4. Integrate with existing Egis XD Flex 2 controller

  5. Air Compressor SPOD Control - Engine Bay SPOD 2, Circuit 7

  6. 30A circuit to ARB Twin Motor
  7. Manual SPOD switch with ignition interlock
  8. Integrate with ARB Pressure Control panel

Tasks: 1. SPOD Power Feeds - [ ] Install 100A input breaker for Engine Bay SPOD 1 - [ ] Install 150A input breaker for Engine Bay SPOD 2 - [ ] Run main power cables from secondary battery to both SPODs - [ ] Establish SPOD ground connections (document locations) - [ ] Label all power connections

  1. Touchscreen Controller Setup (RFI-102 must be resolved)
  2. Mount touchscreen controller in dashboard
  3. Wire controller to both BantamX units
  4. Configure SPOD addresses (SPOD 1 vs SPOD 2)
  5. Test wireless connectivity

  6. Program circuit names in touchscreen

  7. Rigid Ignite Spot Pod Wiring

  8. Route wire from Engine Bay SPOD 1 to roof through A-pillar (per RFI-104)
  9. Install 20A circuit breakers in SPOD circuits 1-2
  10. Connect Rigid Ignite Spot - Right to circuit 1
  11. Connect Rigid Ignite Spot - Left to circuit 2
  12. Install proper connectors (waterproof Deutsch or equivalent)

  13. Test both spots independently and together

  14. Winch Relay Integration

  15. Wire SPOD 2 circuit 6 to winch relay control
  16. Configure momentary trigger in SPOD app
  17. Test winch control from SPOD touchscreen

  18. Verify Egis XD Flex 2 knob still works independently

  19. Air Compressor SPOD Circuit

  20. Wire SPOD 2 circuit 7 to ARB compressor relay
  21. Install ignition interlock (prevent battery drain when off)
  22. Test compressor activation from SPOD
  23. Verify integration with ARB Pressure Control panel
  24. Test manual SPOD control vs automatic pressure control

Testing: - [ ] Test all 3 critical circuits independently - [ ] Verify SPOD touchscreen shows correct status for all circuits - [ ] Test current draw on each circuit (verify within breaker ratings) - [ ] Test in simulated offroad conditions (lights while winching, etc.) - [ ] Verify no voltage drop under load

Deliverables: - 3 functional SPOD circuits for trip safety - Touchscreen controller operational - Updated ELECTRICAL_CIRCUITS.md with circuits 1-2 (SPOD 1) and 6-7 (SPOD 2) marked "✅ Installed" - Installation photos and test results

PHASE 2: Engine Bay SPOD Complete Installation

Status: 📋 Planned Completion Target: February 2025 Prerequisites: Phase 1A and 1B complete

Scope: Complete all 16 engine bay SPOD circuits (8 per BantamX)

Engine Bay SPOD 1 - Remaining Circuits (3-8): - [ ] Circuit 3: Roof Floodlights - Rear (20A, reverse trigger + manual) - [ ] Circuit 4: Roof Chase Light (10A, ignition-on or manual) - [ ] Circuit 5: Rock Lights (10A, courtesy light or manual) - [ ] Circuit 6: Exterior Courtesy Lights (10A, door pin trigger or manual) - [ ] Circuit 7: Halos (5A, ignition-on DRL style) - [ ] Circuit 8: Projector Backlighting (5A, ignition-on or tied to low beams)

Engine Bay SPOD 2 - Remaining Circuits (1-5, 8): - [ ] Circuit 1: Round Bumper Lights - Adapt (30A, manual) - [ ] Circuit 2: Round Bumper Lights - All On (30A, high-beam trigger or manual) - [ ] Circuit 3: Amber Fog Lights (15A, low-beam trigger or manual) - [ ] Circuit 4: White Fog Lights (15A, high-beam trigger or manual) - [ ] Circuit 5: Reverse Lights (10A, reverse trigger + SPOD override) - [ ] Circuit 8: [Spare Slot] - TBD

Critical Tasks: 1. Roof Penetrations (RFI-104 required - Scanstrut routing) - [ ] Install Scanstrut DS-HD6-BLK deck seal for cable bundle - [ ] Route all roof lighting power through single penetration - [ ] Apply BoatLIFE Life-Calk sealant (verify waterproofing per RFI-001) - [ ] Test for leaks (water spray test)

  1. Factory Integration Wiring (RFI-104 required - tap point locations)
  2. Identify and tap reverse light trigger wire
  3. Identify and tap door pin trigger wires
  4. Identify and tap ignition-on power source
  5. Identify and tap low-beam and high-beam trigger circuits
  6. Use proper tap connectors (Posi-Tap or solder + heat shrink)

  7. Install isolation diodes where needed

  8. Testing Each Circuit

  9. Test trigger functionality (does reverse light trigger work?)
  10. Test manual override from SPOD
  11. Verify no interference with factory circuits
  12. Load test all circuits simultaneously (verify input breaker sizing)

Deliverables: - All 16 engine bay SPOD circuits functional - Roof penetration waterproofed and tested - Factory integration complete and documented - Circuit trigger logic verified - Updated ELECTRICAL_CIRCUITS.md with all circuits marked "✅ Installed"

PHASE 3: Interior SPOD & Fuse Block Installation

Status: 📋 Planned Completion Target: March 2025 Prerequisites: Phase 2 complete

Scope: Install interior power distribution (SPOD, fuse block, MSD relays)

Interior SPOD Installation: 1. Physical Mounting (RFI-108 required - exact location) - [ ] Determine exact mounting location "behind 2nd row" - [ ] Fabricate or source mounting bracket - [ ] Install Interior SPOD with 100A MEGA fuse input - [ ] Run power feed from secondary battery or switched main power (clarify source) - [ ] Establish interior ground point

  1. Interior SPOD Circuits (1-5):
  2. Circuit 1: Interior Ambient Lights (5A, door pin + manual)
  3. Circuit 2: Ham Radio 1 (10A, ignition-on)
  4. Circuit 3: Ham Radio 2 Power Pole (10A, manual)
  5. Circuit 4: 400W Inverter (15A, manual with safety label)
  6. Circuit 5: Roof Power for Starlink (10A, manual or ignition-on)
  7. Circuits 6-8: Reserve for future expansion

Interior Fuse Block Installation: 1. Physical Mounting (RFI-109 required - center console vs 2nd row) - [ ] Determine mounting location (center console area or behind 2nd row) - [ ] Install fuse block with 60A MAXI fuse input - [ ] Run key-switched power for circuits 1-2 (front seat heaters) - [ ] Run manual switched power for circuits 3-5 (rear heaters, light bar)

  1. Fuse Block Circuits (1-5):
  2. Circuit 1: Front Driver Seat Power (15-20A, ignition-on)
  3. Circuit 2: Front Passenger Seat Power (15-20A, ignition-on)
  4. Circuit 3: Rear Seat Heater - Right (10-15A, manual SPOD)
  5. Circuit 4: Rear Seat Heater - Left (10-15A, manual SPOD)
  6. Circuit 5: Rigid Adapt 40" Light Bar (30A, manual SPOD)
  7. Circuits 6-8: Reserve for future

MSD Relay Block Installation: 1. Relay Block Setup - [ ] Mount MSD relay block behind 2nd row or under center console - [ ] Wire relay coils to Interior SPOD circuits (low-current control) - [ ] Wire relay loads to Fuse Block circuits (high-current loads) - [ ] Install key-switched relay for fuse block power

  1. MSD Relay Wiring:
  2. Relay 1: Right Rear Seat Heater (Interior SPOD Ckt 3 → Fuse Block Ckt 3)
  3. Relay 2: Left Rear Seat Heater (Interior SPOD Ckt 4 → Fuse Block Ckt 4)
  4. Relay 3: Adapt Light Bar (Interior SPOD Ckt 5 → Fuse Block Ckt 5)
  5. Relay 4: Key Power to Fuse Block (Ignition → Fuse Block Ckts 1-2)

"Behind 2nd Row" Wire Management: - [ ] Install wire management system (junction box or organized loom) - [ ] Route and label all wires converging at this junction: - Engine bay antenna to front fender - Engine bay Ethernet to driver seat - ARB Bluetooth controller - Overhead console Ethernet - Overhead console LEDs - Starlink/Anderson 12V to roof - Door-mounted LED courtesy lights (4x) - Rear seat heater controls - Center console 400W inverter power - Rear bumper antenna - [ ] Create wire routing diagram for this junction - [ ] Install access panel for future service

Deliverables: - Interior SPOD fully functional (5 circuits minimum) - Interior fuse block installed and operational - MSD relay block wired and tested - "Behind 2nd row" junction organized and documented - Updated ELECTRICAL_CIRCUITS.md with interior systems marked complete

PHASE 4: Specialty Circuits & Integration

Status: 📋 Planned Completion Target: April 2025 Prerequisites: Phase 3 complete

Scope: Install remaining specialty circuits and complete system integration

Center Console Circuits: - [ ] Rear seat heater controls (hi/lo for left and right) - [ ] 400W inverter power and outlet - [ ] LED safe light (console vault) - [ ] Cup holder LEDs (split 1 run to 2) - [ ] Remote mic cable for ham radio - [ ] Rigid light bar controller - [ ] 2x USB charging plugs (switched power)

Overhead Console Circuits: - [ ] Ethernet network connection - [ ] LED map lights (2x, split 1 run to 2)

Door-Mounted Circuits: - [ ] LED courtesy lights (4x, one per door) - [ ] Route from "behind 2nd row" through door boots - [ ] Waterproof connections at door hinge area

Rear of Vehicle: - [ ] Ham radio antenna cable to rear bumper - [ ] Coil excess behind 2nd row for service access

Deliverables: - All specialty circuits functional - Center console fully wired - Overhead console operational - All 4 door courtesy lights installed - Complete system integration test

PHASE 5: Testing, Documentation & Labeling

Status: 📋 Planned Completion Target: May 2025 Prerequisites: Phase 4 complete

Scope: Complete system testing, as-built documentation, and professional labeling

System Testing: 1. Individual Circuit Tests - [ ] Test each of 32+ circuits independently - [ ] Measure current draw under load for each circuit - [ ] Verify breaker/fuse sizing is appropriate - [ ] Test trigger logic (door pins, reverse, ignition, etc.) - [ ] Verify no voltage drop under load

  1. Integration Tests
  2. Test worst-case simultaneous loads (all lights on, compressor running, etc.)
  3. Verify alternator output under max electrical load
  4. Test Redarc DC-DC charging under heavy load
  5. Verify solar charging integration (if installed)

  6. Test battery isolation (can secondary battery power loads without primary?)

  7. Safety Tests

  8. Verify all circuits have proper fusing
  9. Test circuit breaker trip points
  10. Inspect all connections for proper crimps and heat shrink
  11. Check all wire routing for chafe points
  12. Verify waterproofing at all exterior connections
  13. Test emergency shutdown procedures

Documentation: 1. As-Built Wiring Diagram - [ ] Create detailed wiring diagram showing actual installation - [ ] Document all wire colors, gauges, lengths - [ ] Document all connector types and part numbers - [ ] Document all tap points on factory wiring - [ ] Document all ground point locations - [ ] Add photos of critical areas

  1. Update ELECTRICAL_CIRCUITS.md
  2. Mark all circuits with "✅ Installed" or "⚠️ Issues" status
  3. Document actual wire gauges used (not just planned)
  4. Add "As-Built Notes" section with deviations from plan
  5. Add troubleshooting section for common issues

  6. Update "Last Updated" date

  7. Create Troubleshooting Guide

  8. Document common failure modes
  9. Create decision tree for diagnosing issues
  10. List spare parts to keep on hand
  11. Document factory integration points for future reference

Labeling: 1. Wire Labels (Both Ends) - [ ] Label every wire at source and destination - [ ] Use format: "SPOD1-C3-FLOOD-R" (SPOD 1, Circuit 3, Flood Right) - [ ] Use waterproof label tape or heat shrink with printing

  1. Circuit Breaker/Fuse Labels
  2. Label all breakers with circuit name and amperage
  3. Create SPOD legend stickers (Switch-Pros x Rigid legends)

  4. Label touchscreen controller with vehicle name

  5. Junction/Connection Labels

  6. Label all major junction points
  7. Create diagram label at "behind 2nd row" junction showing all wires
  8. Label ground points with wire gauge and circuit

Deliverables: - Comprehensive system test report - As-built wiring diagram with photos - Updated ELECTRICAL_CIRCUITS.md with as-built details - Troubleshooting guide - Fully labeled electrical system - Spare parts list with part numbers

Wire and Materials Bill of Materials

NOTE: This section will be populated after RFI-103 is resolved with specific wire specifications.

Wire Requirements (TBD - Pending RFI-103)

  • Determine total length of each wire gauge needed
  • Create wire color coding standard (RFI-110)
  • Source wire from reputable supplier (Waytek, Del City, or equivalent)

Connectors & Terminals (TBD - Pending RFI-103)

  • Deutsch waterproof connectors for exterior circuits
  • Ring terminals (sized for wire gauge and stud size)
  • Butt splice connectors (properly sized)
  • Posi-Tap connectors for factory integration
  • Heat shrink tubing (adhesive-lined)

Fuses & Breakers

  • 100A circuit breaker for Engine Bay SPOD 1
  • 150A circuit breaker for Engine Bay SPOD 2
  • 100A MEGA fuse for Interior SPOD
  • 60A MAXI fuse for Interior Fuse Block
  • Individual circuit breakers/fuses per circuit table

Mounting & Protection

  • Wire loom (split and solid)
  • Cable ties (UV-resistant)
  • Grommets for all penetrations
  • BoatLIFE Life-Calk sealant for roof penetrations
  • Scanstrut DS-HD6-BLK deck seal (roof cable entry)
  • Mounting brackets for Interior SPOD and Fuse Block

Risk Assessment

High Risk Items (Immediate Attention Required)

  1. January 24 Trip Deadline - ARB Pressure Control installation is critical path
  2. Roof Penetrations - Waterproofing failure could cause interior water damage
  3. Wire Gauge Undersizing - Could cause fire or system failure under load
  4. Factory Integration - Tapping factory wiring incorrectly could damage vehicle systems
  5. Grounding Issues - Poor grounds can cause intermittent failures and electrical noise

Medium Risk Items (Monitor Closely)

  1. SPOD Programming - Incorrect circuit configuration could cause confusion or unsafe operation
  2. Trigger Circuit Integration - May not work as expected, require redesign
  3. Wire Routing - Could chafe and short if not properly protected
  4. Connector Quality - Low-quality connectors will fail in harsh conditions

Mitigation Strategies

  • Resolve all RFIs before proceeding - Don't guess, research and confirm
  • Source quality materials - Don't cheap out on wire, connectors, or sealant
  • Test incrementally - Don't wire everything then test, test each circuit as installed
  • Document as you go - Take photos, label wires, update docs in real-time
  • Professional help when needed - Complex integrations may need Evolution Garage (Justin in Tavares, FL)

Success Criteria

Phase 1 Success (Pre-Trip)

  • ARB Pressure Control panel fully functional
  • Dual battery charging system verified working
  • Rigid Ignite Spot Pods operational
  • Winch and air compressor SPOD-controllable
  • All systems tested under simulated offroad conditions

Phase 2-3 Success (Complete Installation)

  • All 24+ circuits functional
  • All factory integration working correctly (triggers, etc.)
  • No voltage drop issues under load
  • SPOD touchscreen shows accurate status for all circuits
  • Roof penetrations 100% waterproof (tested)

Phase 4-5 Success (Final System)

  • All circuits tested independently and in combination
  • As-built documentation complete and accurate
  • All wires labeled at both ends
  • Troubleshooting guide created
  • System ready for long-term reliable operation

Contact Information

Technical Support

  • Evolution Garage (Justin): Tavares, FL - Specialist for complex electrical work
  • Switch-Pros Support: Technical assistance for BantamX configuration
  • IH8MUD Forum: Community knowledge base for LC100/LX470 electrical systems

Suppliers

  • Wire & Connectors: Waytek, Del City, Amazon (quality brands only)
  • Sealant: West Marine, Defender Marine (BoatLIFE products)
  • Electrical Components: Amazon, SLEE Off-Road, SDHQ Off-Road

Notes

Implementation Philosophy

  • Safety First: Every circuit must be properly fused, grounded, and protected
  • Quality Over Speed: Take time to do it right, don't rush critical installations
  • Document Everything: Future-you will thank present-you for good documentation
  • Test Incrementally: Catch problems early when they're easy to fix
  • Professional Standards: Crimp and solder all connections, use heat shrink, route cleanly

Common Pitfalls to Avoid

  • ❌ Skipping RFI resolution and "winging it"
  • ❌ Using incorrect wire gauge for amperage and length
  • ❌ Poor crimps or connections (will fail under vibration)
  • ❌ Inadequate waterproofing on exterior circuits
  • ❌ Not labeling wires (impossible to troubleshoot later)
  • ❌ Not testing circuits before buttoning up panels
  • ❌ Trusting online diagrams without verification for your specific vehicle

Status: 🔄 Phase 1A In Progress (winch and solar pending) Last Updated: 2025-12-28 Next Review: After winch installation complete Related Documents: - technical-specs/ELECTRICAL_CIRCUITS.md - As-built electrical system documentation - planning/WINCH_INSTALLATION_CHECKLIST.md - Detailed winch installation procedure - RFI.md - Research questions blocking installation (RFI-101 through RFI-111) - STATUS.md - Current system status and trip readiness