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Thread: Handy electrical tool, relay extender

  1. #1
    Senior Member Bitsyncmaster's Avatar
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    Handy electrical tool, relay extender

    Here is a handy tool I build a long time ago to troubleshoot electrical problems. Lets you test relay connections without pulling up the relay bank.
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    Dave M vin 03572
    http://dm-eng.weebly.com/

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    Senior Member DMC5180's Avatar
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    Quote Originally Posted by Bitsyncmaster View Post
    Here is a handy tool I build a long time ago to troubleshoot electrical problems. Lets you test relay connections without pulling up the relay bank.
    Great idea.

    Unfortunately, Iíve always had difficulty sourcing the Male terminals and housing though.
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    Senior Member Bitsyncmaster's Avatar
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    Quote Originally Posted by DMC5180 View Post
    Great idea.

    Unfortunately, Iíve always had difficulty sourcing the Male terminals and housing though.
    I will look for part numbers. I used the pins from my fan Zilla unit that I removed from my car.
    Dave M vin 03572
    http://dm-eng.weebly.com/

  4. #4
    Senior Member Bitsyncmaster's Avatar
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    These are the pins Zilla used:

    https://www.mouser.com/ProductDetail...2VTEEAwDfP0%3D

    Those are for 14-12 AWG wire. I using 16 AWG just double over the wire to get 12 AWG thickness.

    Now Zilla used a standard socket shell designed for the female relay pins but he cut the holding tabs on the pins a little, installed the pin so the tab would not latch in the normal location but would latch on the top of the shell. There must be a shell made for these pins but the pins would not extend as far as the Zilla setup.
    Dave M vin 03572
    http://dm-eng.weebly.com/

  5. #5
    LS Swapper Josh's Avatar
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    Thanks for this Dave.

    Lots of neat pins in the FASTON catalog.

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  6. #6
    Senior Member Bitsyncmaster's Avatar
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    Well I though of a better way than using the cut latching finger and latching on the top of the shell. Still using the same shell as the female pins but cutting some of the top off the shell and seating the pins normally. On my next mouser order I will buy some pins and shells and make up a few of these tools.

    I thought of another use for this tool. Measuring the currents of each of the relays. You extend the relay and then can clamp on the DC amp meter (clamp type). I will use 12 AWG on all five pins so it also will work for the fan fail to extend it.
    Dave M vin 03572
    http://dm-eng.weebly.com/

  7. #7
    Senior Member Bitsyncmaster's Avatar
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    I got some of those pins and they are the same one Zilla used so it does work the way Zilla did it (cutting the latching finger a little and sticking the pin in rotated). But there must be a socket made for these pins. Maybe not the 5 pin ISO relay but the pins are made to install in a socket. Not a big deal since these are just test tools.

    I could 3D print one but again, just a test tool.
    Dave M vin 03572
    http://dm-eng.weebly.com/

  8. #8
    Senior Member Bitsyncmaster's Avatar
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    Well I did end up doing a 3D print for the connector shell using the male pins for the mini-ISO-relay. This is with 14 AWG wire which crimps nice with my crimper. I did not like the crimp using 12 AWG wire so I ordered a new crimper. So this works without any pin modification and holds the pins correctly.

    I think I will make the shell a little longer and put a rim on it so it's easy to pull out of a relay bank.
    Attached Images
    Dave M vin 03572
    http://dm-eng.weebly.com/

  9. #9
    Senior Member Bitsyncmaster's Avatar
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    I printed 7 of my male sockets in black resin. You really have to be sure all the resin is washed out of the small opening of the pins before you post cure the parts. I finished one with 12 AWG wire and also crimped a 20 AWG wire into the pins so I can attach a meter or scope probe to any pin. To measure the current you would just clamp on a DC current probe over the wire you want to measure.

    I'm not adding these to my product list since I'm so busy now trying to keep up with my other products.
    Attached Images
    Dave M vin 03572
    http://dm-eng.weebly.com/

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