This past weekend I decided it was time to do some work on Missy’s dash and wiring.
She originally had an audio/visual system that included numerous video screens for the passengers to view movies and such. A great deal of wiring was routed thru the J-box and dash to a control head mounted where my backup video camera screen is now located. By the way, the J-box is this “compartment” at the front of the driver’s side of the bus.
A whole slew of things come together in the J-box – wiring, hydraulic lines, air lines, etc.) so they call it the “Junction Box” or J-box. There were also several components in the J-box that I think were related to vehicle fleet tracking such as an old GPS/cellular data device, power supply, antenna, and more wiring. The left hand panel had four or five switches/buttons that did absolutely nothing so I figured they were related and could also be removed. However; I couldn’t be sure until I traced the wires.
All of this “needed” to come out. It was ugly, took up a lot of space, and was unused. It could have been left in place but my brain knew it was useless, thus the “need” to remove it.
The left hand dash/switch panel had to come out.
As well as the right hand switch panel. I have a replacement for this panel waiting to be installed as the existing one is cracked and broken in many places. I figured it would crumble into many bits as soon as I started messing with it – and it did!
To access the wiring behind the dash, the three lower dash “kick panels” had to come out as well. I was afraid what I mind find under there once removed. In terms of dirt, grime, and yuck – Missy has had a good bit of it in every nook and cranny. Under the dash proved no different and even the J-box. So, cleaning was a big part of this project.
The rotary headlight switch has been showing signs of falling apart so I was a little nervous about it as well. Of course, that switch also crumbled as soon as it was touched. Only $155 for a replacement! 🙂 Actually, while certainly not excited about the price, the fact that a replacement is even available really is a big positive. Below is a ‘good’ switch on left, the crumbling ‘bad’ switch on the right.
The dash lights dimmer switch was also in ‘barely working’ condition so ordered a new one of those as well.
With everything exposed and all tie wraps – that I could find – snipped, I started gently pulling out the wires that were no longer in use. Nothing difficult about that but I always try to be very careful doing this as pulling out wiring that should not come out always seems to result in a much bigger repair job. As you can see, a pretty big pile of wire came out.
Next was the vehicle tracking “stuff”. Once again, a good number of bits and wiring ended up on the ground. The photo doesn’t do it justice as there is no scale – it is a big pile!
Routing the backup camera wiring from the J-box and behind the dash was next. This wiring has been exposed since I installed the cameras (backup and roof) – very temporary. For a permanent and professional looking install, the wires had to be hidden. My handy-dandy electrical snake from Amazon went into action and did a fine job for me once again! I’m not sure how I lived for so many years without one of these snakes.
It was time to remove all the switches from the right hand switch panel. I REALLY wanted to avoid breaking a bunch of things while doing this so I was very gentle. All came apart reasonably well which left me with a pile of switches that were grimy and gross (this photo is actually AFTER cleaning).
The bus boys seemed like they really wanted to help – thorought the project. They were sticking their nose into every little thing I disconnected and constantly involved. Since they like to clean themselves – I thought they might enjoy this cleaning project so I handed it off to them. I turned around once and what happened?!?!?
THIS! Not more than ten seconds after I gave them something to do!
It’s almost like they are kids or something…
So, I used some of MY elbow grease to clean them up as well as possible. A couple switches will not be used any longer and will be removed – such as the passenger light and blower switches.
I would really like to paint or cover the existing dash panels and kick panels. The off-white color is VERY dated and generally pretty ugly. However; I can’t decide what would be appropriate. I suspect some sort of upholstery covering would be best. I’ll likely leave them for now until the right choice has become obvious – maybe after the new driver/passenger captain’s chairs, flooring, and other details are in. Of course, one could argue that anything would be better than the current color!!! 🙂
The left hand armrest/panel – in addition to the previously mentioned buttons – had two cigarette lighter style power sockets, only one of which worked. Also a microphone jack and two 12 VDC power sockets that were very non-standard (maybe custom for a particular device – which no longer exists on board). Some goofball decided to “burn” cigarette lighter circles in the panel which make it look pretty bad – and it is cracked and very aged. However; a replacement panel is not available so I have to work with what I have (and I’m keeping an eye open for a good salvaged panel – if anyone spots one, let me know please). I added two USB charging ports to the panel, fixed the power socket that was not working, and added a 5.5 mm power socket.
The little fan I’ve been using to stay cool while driving has been a real nuisance. It is not mounted to anything and really likes to go flying at every opportunity. It was time to get it mounted to avoid being whacked in the head by a flying fan, again. Finding a good spot was the most difficult bit. I do not like wasting valuable real estate with rarely used items. On the wall above me was about the best option available. It even afforded pretty simple mounting and wiring. Plus, if it ever falls, I will know immediately! I may even use the previously mentioned “blower” switch to control this fan.
More connectors and “stuff” that was removed.
At this point, there is not much left to do but wait for the new rotary headlight switch, dimmer switch, panels blanks. Once those are in, I will reassemble the dash and see if Missy still runs and the various switches still work like they should! 🙂
In the meantime – Missy’s dash looks like an open heart surgery that was canceled half way thru…
It appears you’ve got quite busy since we talked on the 28th. There must be 1,000 miles of wire through out Missy. Far beyond my ability to figure it out! Given enough time… she’ll be like ‘brand new’!
Definitely busier than I had been!! I’ve made a lot of good progress over the last week or two – still have to get it written up and posted.
Holy cow!!!! That is a little scary! I have been trying to fix a few things here but nothing as complex as that. The J-box is looking better however!