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Old 06-24-2016, 10:16 PM   #141
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Quote:
Originally Posted by Rich.M View Post
Electrical problem originates at the Curt controller, part of the electrical system also used by trailer electrical. You can have a short due to water infiltration without towing.
I was crawling around under my 2017 Suseeker this afternoon. had to readjust the location of some wiring so I could install an extenda stay propane system. One shocking thing I did find is that when forest River splices wires they use those push on connectors. They usually aren't a problem when they are sealed properly. Trouble is the connectors they used are for interior dry locations and were never waterproofed. Tomorrows task will be getting out the tube of RTV and sealing every connector I can find underneath.

Water, Electricty, and copper wire lead to corrosion and future failure if not addressed.
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Old 06-29-2016, 11:35 AM   #142
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Finally done

Yesterday, I completed the Curt controller install in a weatherproof PVC box. Many thanks to a couple of the posters here who provided inspiration and ideas for my install.

I did something of a hybrid approach - the Curt controller inside the box and the load resistors and relay on the outside. I used Dow Corning DC-4 (dielectric grease) on all connections that might be susceptible to water intrusion. I kept the resistors on the outside of the box and mounted them to an aluminum plate (0.063 thick) as an additional heat sink - per the suggestion of one poster. The relay is supposed to be weatherproof, as is the connection, but I will carry a spare relay and it's about a 30 second replacement if it fails. I fabricated a small hangar for it and riveted it to the plate, as well.

I purchased a couple of Deutsch connectors (receptacles) and replaced the ends on the Curt controller with them. They are mounted through the weatherproof box and allow the factory (FR) wiring to connect to the controller without the risk of water getting through the box. This was a little more time consuming and expensive, but I think the results are pretty good.

I attached the entire assembly to the frame using high strength (175 lbs. each) cable ties passing through the aluminum plate I attached to the back of the PVC box. Although I would normally prefer to drill through and use bolts or sheet metal screws, I did not want to risk drilling into the FR frame extension. The box is protected aft of the BigFoot leveler and so I think the risk of damage to the box is very small.

Although I enjoyed fabricating the aluminum plates and enclosure, having to provide a fix for poor engineering and installation from FR really annoys me. I spend more time fixing defects, lousy build quality and bad design than camping. The line "it's part of the RV experience" wears a bit thin.
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Old 06-29-2016, 12:29 PM   #143
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Originally Posted by KatanaPilot View Post
Yesterday, I completed the Curt controller install in a weatherproof PVC box. Many thanks to a couple of the posters here who provided inspiration and ideas for my install...
WOW - GREAT WORK ! FR should hire you !

Two questions -

1. Did you have to purchase a crimper for the Deutsch connectors, and if so, did you go with an inexpensive one, or the expensive Deutsch crimper ?

2. Where did you get the connector mounts attached to the box - were they fabricated ?

Great job ! Now I have my work cut out for me !
Jeff
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Old 06-29-2016, 12:58 PM   #144
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Thanks!

Quote:
Originally Posted by nusslejj View Post
WOW - GREAT WORK ! FR should hire you !

Two questions -

1. Did you have to purchase a crimper for the Deutsch connectors, and if so, did you go with an inexpensive one, or the expensive Deutsch crimper ?

2. Where did you get the connector mounts attached to the box - were they fabricated ?

Great job ! Now I have my work cut out for me !
Jeff
You are one of the folks that motivate me to get this stuff done! And FR can't afford me

1. Didn't need a crimper at all. Simply removed the pins from the factory Deutsch connector and installed them into the new Deutsch receptacle. The pins remove very easily once you remove the rubber plug that is installed in the pin end of the connector.

If I get a spare Curt controller, I will want to install pins on it for easy replacement on the road - so I will see if my weatherpack crimper will work, or will buy one that does. I'm a tool hound, so I usually go for the better tool if I can afford it.

2. I bought the flange mount receptacles here
They are a Deutsch part - only fabrication is drilling and cutting the appropriate sized opening in the PVC box. There are templates on the Batts Racing website for each of these connectors.

The aluminum plates were done really as an excuse to work on some of my sheet metal skills. I'm building an airplane, so I need to practice on as much non-critical fabrication as I can.
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Old 06-29-2016, 04:35 PM   #145
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Two more pictures

Attached is a picture looking aft from in front of the BigFoot stabilizer.

The second picture is of a couple of harnesses of unknown function. Judging by the location and the color of the wires, I assume this is the interface from the MB factory tow package wiring to the FR wiring for the Curt controller, taillights and tow harness. So just to be safe, I disconnected them and packed them full of dielectric grease, too.
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Old 07-01-2016, 05:08 PM   #146
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Kahana pilot,
Nice job! I just had to replace the Curtis controller on my newly acquired 2015 Solera as the right directional and brake light wasn't working. Wish I had the time to enclose it but we are leaving on a two month trip. Instead I replaced it with the Hopkins unit.
I saw you are building an airplane. With the quality you showed with this modification you should do great on an airplane! My wife and I are working on our 7th homebuilt. Oshkosh is on our trip itinerary as we have been there for the last 30 plus years.
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Old 07-01-2016, 07:08 PM   #147
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Thanks much!

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Originally Posted by Philrisl View Post
Kahana pilot,
Nice job! I just had to replace the Curtis controller on my newly acquired 2015 Solera as the right directional and brake light wasn't working. Wish I had the time to enclose it but we are leaving on a two month trip. Instead I replaced it with the Hopkins unit.
I saw you are building an airplane. With the quality you showed with this modification you should do great on an airplane! My wife and I are working on our 7th homebuilt. Oshkosh is on our trip itinerary as we have been there for the last 30 plus years.
If you are wandering around Camp Scholler and see a Forester MBS with a silver Honda Fit in tow with Florida plates, stop in and say hello.

I'm building an RV-10 and it's my first homebuilt. Big project, but we live in an airport community and there is lots of expertise here.
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Old 07-01-2016, 08:03 PM   #148
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We will be in the ultralight camping from Friday before the show until the end. Solara towing a red Harley Electra glide Ultra. Touch base at floatfly0(at)gmail.com
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Old 07-02-2016, 04:16 AM   #149
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Where are you located in Florida? I am in Deltona, fly out of Deland (DED).
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Old 07-02-2016, 10:07 PM   #150
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We live in Destin and also have a home south of Atlanta on a fly-in community.
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