Customizing a Big Rig
You are working on the 2000 International 9400 truck in the shop. A customer wants to customize it with yellow side marker lights along the bottom trim and up the back flaring. You have seen trucks running on the highway with extra lights all over them. Some shops specialize in customizing the trucks to look like the way they do. The customer provided a picture of the truck with the locations of where he wants the lights placed. (See the orange rectangles in the picture.) If he likes your work, he'll want more lighting added in the future.
Check out this video from the annual St Ignace / Mackinaw City Truck Show.
Check out this video from the annual St Ignace / Mackinaw City Truck Show.
Task
You need to determine the lighting circuitry and components needed to complete the job. You will need to determine
1. Number of lights
Look at the picture and determine the number of lights. Don't forget both sides.
2. The correct lights for the application
Use the Grote Catalog to find the lights you would install. The product catalog lists different lights and their amp draw.
3. A wiring schematic
Draw out a schematic using proper symbols and circuits. Here's a site to help you out.
Take a quiz to check your knowledge of symbols and circuits
4. The wire sizing and length
The length of wire and the total amp draw of the circuit will determine the wire size. Too small of wire will cause a voltage drop and dim bulbs. Too big of wire will be more costly to the customer. Scroll down on this site to check the comparison of amp draws, wire size and voltage drops.
5. Switches and circuit protection
Use the Grote Catalog to identify proper switches and circuit protection. You will need these components to be rated for the amperage of the circuits you have designed. This is a specification catalog, but doesn't have prices.
6. Prices
Class 8 Truck Parts is a supplier of components. Some suppliers list all specifications but most limit product information to part number, price and limited specifications.
1. Number of lights
Look at the picture and determine the number of lights. Don't forget both sides.
2. The correct lights for the application
Use the Grote Catalog to find the lights you would install. The product catalog lists different lights and their amp draw.
3. A wiring schematic
Draw out a schematic using proper symbols and circuits. Here's a site to help you out.
Take a quiz to check your knowledge of symbols and circuits
4. The wire sizing and length
The length of wire and the total amp draw of the circuit will determine the wire size. Too small of wire will cause a voltage drop and dim bulbs. Too big of wire will be more costly to the customer. Scroll down on this site to check the comparison of amp draws, wire size and voltage drops.
5. Switches and circuit protection
Use the Grote Catalog to identify proper switches and circuit protection. You will need these components to be rated for the amperage of the circuits you have designed. This is a specification catalog, but doesn't have prices.
6. Prices
Class 8 Truck Parts is a supplier of components. Some suppliers list all specifications but most limit product information to part number, price and limited specifications.
Process
You will work with a partner to complete the estimate. The truck is in the shop to make measurements on to determine component location and wire length. Lights and circuits need to be run in parallel and switches and circuit protection need to be run in series. The frame will be acting as a ground but you will be mounting most of the lights to fiberglass and plastic. You will determine amperage of single lights and complete circuits from which you determine wire and component sizing. You will be working with web resources to identify lights and specifications needed to complete the job properly. You will draw a schematic, using proper symbols, of the electrical circuits required to install the customer requested items. You will make a list of all components including quantity, part numbers, descriptions, specifications and price using an Excel spreadsheet. You will present your estimate to the class upon completion. Your project will be evaluated using the rubric below.
Conclusion
The students estimated a customers request for customization. They identified all the components needed and used Ohm’s Law to determine amperage flow in the circuits. They used online resources to determine requirements, locate components, and interpret informational charts. They used an Excel program to create a spreadsheet to categorize the customer’s material list. They completed their project by presenting to the class.
Follow up questions:
How can you reduce amperage draw of the circuits? What components were redundant? What can be done to reduce the sizing of components? What could be done to make a better presentation?
Follow up questions:
How can you reduce amperage draw of the circuits? What components were redundant? What can be done to reduce the sizing of components? What could be done to make a better presentation?
Resources
http://www.powerstream.com/Wire_Size.htm
http://www.rowand.net/Shop/Tech/WireCapacityChart.htm
http://www.the12volt.com/ohm/ohmslaw.asp
http://www.wiringdiagrams21.com/2008/11/01/wiring-diagrams-symbols
http://www.truck-lite.com/webapp/wcs/stores/servlet/TopCategoriesDisplay?catalogId=10001&storeId=10001&langId=-1
http://grote.com/prodcat/
www.class8truckparts.com
http://www.rowand.net/Shop/Tech/WireCapacityChart.htm
http://www.the12volt.com/ohm/ohmslaw.asp
http://www.wiringdiagrams21.com/2008/11/01/wiring-diagrams-symbols
http://www.truck-lite.com/webapp/wcs/stores/servlet/TopCategoriesDisplay?catalogId=10001&storeId=10001&langId=-1
http://grote.com/prodcat/
www.class8truckparts.com