Freelander 1 Freelander EV

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I've been having issues with the connections in the two small electrical boxes as everything is crammed in pretty tight.
I'm still unsure how much will change over the months and years ahead so I'm reluctant to cut all cables to length and solder all the connections so have decided to replace the two small boxes with something a bit bigger. My first thought was to buy a box but there is nothing available with the dimensions I need so I tried 3D printing a box. This was going great as you can see but it was taking so long I had to turn off the printer at bedtime. This is normally not a problem as it should pick up again where it left off. Except this time it didn't! :mad:

This is about 2/3 the height I need.
IMG_20231117_113548550.jpg


So this is would have been half of the box as my printer is not large enough to print it all in one go. I was planning to print the two halves over several days and glue them together. It was going great right up to it wasn't. :confused:
So instead I've ordered some sheets of ABS which I plan to either cut and stick together or heat with a heat gun and bend into shape. https://amzn.to/3SJ2x3C If this proves too flexable I'll try acrylic but I find it is a bit brittle.

Any suggestions welcome, I need approx 400mm long by 115mm wide by 95mm high.
 
Making a plastic box from sheet isn't fun. When gluing plastic, you need to use a solvent glue for the material used, or it just won't stick correctly.

I prefer to make boxes out of aluminium because it folds easily, and the corners can be strengthened with aluminium angle if needed.

However for electrical use plastic will be safer than metal.

If I had a suitable 3D printer, I'dprint a box like you.
 
That’s quite a ‘long and thin’ shape, not sure you’ll get a box off the shelf like that.
Could you use some sort of electrical trunking as a box? You can get in 100x100, and cut to whatever length you want (400mm). You’ll even get end caps available.
1700295378008.jpeg
 
Nodge68 said:
Making a plastic box from sheet isn't fun. When gluing plastic, you need to use a solvent glue for the material used, or it just won't stick correctly.

I prefer to make boxes out of aluminium because it folds easily, and the corners can be strengthened with aluminium angle if needed.

However for electrical use plastic will be safer than metal.

If I had a suitable 3D printer, I'dprint a box like you.
Click to expand...

Freddie17 said:
That’s quite a ‘long and thin’ shape, not sure you’ll get a box off the shelf like that.
Could you use some sort of electrical trunking as a box? You can get in 100x100, and cut to whatever length you want (400mm). You’ll even get end caps available.
View attachment 302857
Click to expand...
Good call on the trunking but have you seen the price of it. 😲
I got a couple of A3 sheets of 3mm ABS so will give folding a try. I'll need to cut ends and glue them in but hopefully it will work out OK. If folding the first one is a disaster I'll cut the second and use the dodgy folded one to make ends for the second.
Hopefully tiger seal will be ok for gluing it together.
I had thought of alloy and have some to try if the plastic doesn't work out but like you said plastic is safer.
If I do use the alloy I'll ensure it is well insulated.
 
So the bending went better than expected.
IMG_20231118_164929549.jpg

IMG_20231118_172837984.jpg


But it turns out tiger seal doesn't glue ABS very well. :confused:
IMG_20231118_175332432.jpg
IMG_20231119_092718466_HDR.jpg


I was thinking of calling into Screwfix to get some plastic solvent glue.
They have two types so if any of you know which I should get please say.
Screenshot from 2023-11-19 09-50-49.pngScreenshot from 2023-11-19 09-50-23.png
 
Alibro said:
So the bending went better than expected.
View attachment 302965
View attachment 302964

But it turns out tiger seal doesn't glue ABS very well. :confused:
View attachment 302966View attachment 302967

I was thinking of calling into Screwfix to get some plastic solvent glue.
They have two types so if any of you know which I should get please say.
View attachment 302968View attachment 302969
Click to expand...
I’ve used pipe weld… worked well on drain pipes, so would assume it’ll do the job. Be aware, it sets really quick!
Would plain CA glue work (with a spray of accelerator)?
 
Freddie17 said:
I’ve used pipe weld… worked well on drain pipes, so would assume it’ll do the job. Be aware, it sets really quick!
Would plain CA glue work (with a spray of accelerator)?
Click to expand...
I think CA glue would work but I think something that melts the plastic together should be stronger.
CA is great for some things and just OK for others.
 
Alibro said:
I think CA glue would work but I think something that melts the plastic together should be stronger.
CA is great for some things and just OK for others.
Click to expand...
For ABS, I believe solvent weld domestic waste pipe is ABS, so the solvent glue should work.
 
Alibro said:
New vid

Click to expand...

Excellent Ali. I'll have a watch later.
bukko said:
I replaced the lighter socket with a twin usb socket on my Defender, then realised I had so many different devices (e.g. tyre inflator) that needed a lighter socket! 🤦‍♂️
Click to expand...
The Freelander 2 comes with 3 power sockets, so I've got USB plug things in all of them.
I don't need a plug in tyre inflator, as I've got a battery one which is a good improvement without leads inside the vehicle.
 
bukko said:
I replaced the lighter socket with a twin usb socket on my Defender, then realised I had so many different devices (e.g. tyre inflator) that needed a lighter socket! 🤦‍♂️
Click to expand...
Nodge68 said:
Excellent Ali. I'll have a watch later.

The Freelander 2 comes with 3 power sockets, so I've got USB plug things in all of them.
I don't need a plug in tyre inflator, as I've got a battery one which is a good improvement without leads inside the vehicle.
Click to expand...
I'll maybe refit the power socket in the arm rest. There are heavy cables already there that are not being used in my car.

On a more exciting note I finished replacing the two small boxes with my DIY one and tested the car again.

Before
IMG_20231120_210313336.jpg

After (although not finished yet)
IMG_20231122_202901190.jpg


First test drive was not great as the car stopped after less than a mile. 😯
A quick reset and we were away again..... for another half mile or so. :oops:
Eventually I realised it was the brake boost pump kicking in that caused the problem so after some rewiring to isolate the vacuum pump from everything else I took it out for a test drive and it seems to be sorted. 😊

I guess after making a lid for it the next priority is the heater. ;)
 
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Nodge68 said:
It's coming on well Ali.
Click to expand...
Thanks mate, I was a little down hearted this week as I wasn't sure why it was cutting out. I guessed it was due to all the electronics and cables being jammed in small boxes but until tonight I wasn't sure.

I think a wee Jamisons to celibrate is in order after the red is finished.
It would be rude not too. 😋
 
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