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Discussion Starter #1 (Edited)
I have "finished " my electrical for now and thought I would share some pictures. I am going to put up a shopping list from Amazon of all the pieces and parts for those who want it.

Put a Superwinch 45s on for my Denali plow with hydroturn that I picked up for a great price back in August.
Some interior LED lights under the dash
2 - 6 LED lights on the front
12" spot flood LED for reverse mounted to a switch
An auxiliary harness with weatherpack that can reach into the bed. Originally put there for some bed light but now is used for my plow flashing LED and will be used for other stuff in the bed that I will need power for.
Relocated the heated seat switches
Added the Polaris plow shifter
Added an off/on switch that provides power to the momentary winch switch and the shifter winch/plow switch
Added an exterior switch on the front bumper - near the weatherpack for the hydroturn - for the winch that operates with keyed power OFF. very useful when hooking up and detaching the plow.

Blue seas fuse box
PAC 80
4ga to the Aux post and to the contactor(s)
6ga to the blue seas

OTRATTW Factory Contura switches. Used the terminals and bought a Crimper. They are really nice when messing around in the dash. Highly recommend.

Oooooga Horn as an added bonus.

I learned a ton. Took way longer than I thought.
It looks good from far, but far from good. The Northstar has so much under the hood with the washer tank that it was hard to get everything in there looking good. Space behind the dash with the heater made everything back there difficult too. Wire loom to try and tidy things up. Lots of heat shrink and quality connectors. May have one or two left to replace.

Things that I would change:

Order more wire - I was on the edge of being short a few times.

Spend some more time when I was running the wire from the dash to the fuse block. I did just a hour or two at a time so I would have the buggy tore apart and then have to put it together so we could use it until the next chance I got to go work on it. I would have loved to run all 6 or 8 at the same time.

I would also just run 14ga for everything that I needed and forget the 16 and 18.





Shopping List:

Amber Flashing Light: https://www.amazon.com/gp/product/B01K9X1ZCE/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1
Classic Antique car horn: https://www.amazon.com/gp/product/B0039M7NHY/ref=oh_aui_detailpage_o00_s01?ie=UTF8&psc=1
Lighted horn switch:https://www.amazon.com/gp/product/B0144DKLW0/ref=oh_aui_detailpage_o01_s01?ie=UTF8&psc=1
LED Bar Clamp for front bumper: https://www.amazon.com/gp/product/B01FETT3FO/ref=oh_aui_detailpage_o00_s02?ie=UTF8&psc=1
PAC-80 80-Amp battery isolator: https://www.amazon.com/gp/product/B001EAWS6O/ref=oh_aui_detailpage_o03_s00?ie=UTF8&psc=1
6 LED Lights for front Bumper: https://www.amazon.com/gp/product/B00EA0ZB7I/ref=oh_aui_detailpage_o03_s01?ie=UTF8&psc=1
12” dual row Spot Flood combo (backup Light) https://www.amazon.com/gp/product/B00WE46ZWC/ref=oh_aui_detailpage_o02_s00?ie=UTF8&psc=1
Polaris glacier pro plow controller (2 needed if you have a hydroturn) https://www.amazon.com/gp/product/B008Y2P5D8/ref=oh_aui_detailpage_o01_s03?ie=UTF8&psc=1

6ga 5/16” crimp lugs: supplied with cable
6 ga ¼” Copper Lugs https://www.amazon.com/gp/product/B00O7S7INS/ref=oh_aui_detailpage_o04_s00?ie=UTF8&psc=1
6ga #10 Copper lugs https://www.amazon.com/gp/product/B00EB44OT4/ref=oh_aui_detailpage_o05_s00?ie=UTF8&psc=1
4ga 5/16” crimp lugs: supplied with cable
4ga ¼” Copper Lugs https://www.amazon.com/gp/product/B00O7S7FOK/ref=oh_aui_detailpage_o06_s00?ie=UTF8&psc=1
6 ga battery Cable – 15-ft https://www.amazon.com/gp/product/B0161FVWOK/ref=oh_aui_detailpage_o06_s00?ie=UTF8&psc=1
4ga battery cable – 15ft https://www.amazon.com/gp/product/B0161KSOXM/ref=oh_aui_detailpage_o08_s00?ie=UTF8&psc=1
Heat Shrink Ring Crimp Connector 16-14 AWG https://www.amazon.com/gp/product/B019MC5Y2U/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1
Heat Shrink Ring Crimp Connector 22-16 AWG https://www.amazon.com/gp/product/B019LGLSYA/ref=oh_aui_detailpage_o01_s04?ie=UTF8&psc=1
Cable lug Crimper: https://www.amazon.com/gp/product/B00MVE48Z6/ref=oh_aui_detailpage_o07_s00?ie=UTF8&psc=1
480 Piece Connector Kit: https://www.amazon.com/gp/product/B00H1O0WOM/ref=oh_aui_detailpage_o09_s00?ie=UTF8&psc=1
Ratcheting wire terminal cable crimper: https://www.amazon.com/gp/product/B0069TRKJ0/ref=oh_aui_detailpage_o09_s00?ie=UTF8&psc=1
Delpji-packard Style crimper (OTRATTW and weatherpack connectors) https://www.amazon.com/Delphi-Packard-Five-cavity-Wide-range-Crimping/dp/B003MWJ6SA/ref=sr_1_5?ie=UTF8&qid=1481638113&sr=8-5&keywords=weatherpack+crimper
Weatherpack 2 Pin terminal 14-16 AWG https://www.amazon.com/dp/B004DVM7RG/ref=pd_luc_rh_bxgy_01_03_t_img_lh?_encoding=UTF8&psc=1 Can be found much cheaper on Ebay!

5-pack of 30/40 amp realy harness 12v Bosch Style:https://www.amazon.com/gp/product/B017VDI0GY/ref=oh_aui_detailpage_o09_s00?ie=UTF8&psc=1
Fuses: https://www.amazon.com/gp/product/B0042XORMI/ref=od_aui_detailpages00?ie=UTF8&psc=1
Blue Seas 12 circuit with Negative Bus and Cover : https://www.amazon.com/gp/product/B001P6FTHC/ref=od_aui_detailpages00?ie=UTF8&psc=1
Heat shrink tubing (marine self adhesive) https://www.amazon.com/gp/product/B018GVR0NE/ref=od_aui_detailpages01?ie=UTF8&psc=1 may need more than one

GXL Wire:
Black 18ga https://www.amazon.com/gp/product/B01FMV71O4/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1
Black 14ga https://www.amazon.com/gp/product/B01H9IYSEE/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1
Black 16 ga https://www.amazon.com/gp/product/B01H0LPPYC/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1
18ga 10 colors 10-ft long https://www.amazon.com/gp/product/B01FJ1QYTU/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1
16ga 10 colors 10-ft long https://www.amazon.com/gp/product/B01FJ2PYYU/ref=od_aui_detailpages00?ie=UTF8&psc=1
14ga 10 colors 10-ft long https://www.amazon.com/gp/product/B01FJ35G56/ref=od_aui_detailpages00?ie=UTF8&psc=1

Bussman CB185-80Amp Breaker: https://www.amazon.com/gp/product/B001PTBVLW/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1

Braided Sleeving: https://www.teamconcours.com/store/#!/Braided-Sleeving-3-8-Red-per-foot/p/59328283

OTRATTW Contura X Switches: https://otrattw.net/Contura-X/
OTRATTW Rear Connector housing : https://otrattw.net/Terminals-and-Terminal-Housings/
OTRATTW Packard Terminals: https://otrattw.net/Terminals-and-Terminal-Housings/?page=2




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Rob, really nice work.
I like the relocation of the heated seat switches and winch switches.
 

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Nice work!
What is the PAC 80 for?
 

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Looks good! Have you thought about painting the PVC pipe black?
 

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Discussion Starter #5
Now that is a backup light!
What song does the horn play?
Hey - I learned lighting from you!

It's a klaxon or AOOOGA horn - like an old model T ::tongue-new:
 

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Discussion Starter #6
Nice work!
What is the PAC 80 for?
PAC 80 provides keyed power only to my fuse box. I have too many people in and out of mine and I am worried of killing the battery by someone knocking a switch and me not realizing it. I may add a small fuse box for constant on power for a few things that I want to be able to use w/o keyed ignition.
 

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Discussion Starter #7
Looks good! Have you thought about painting the PVC pipe black?
thanks for the idea -

I am stopping at Menards tonight and I will take a look at the Spray paint for plastic - would make that look not so cobbled up. I like the fact that I can just pull that off and put it in the bed and not drive around with my idiot light on a stick. My wife rolls her eyes at me.
 

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Nice! Really impressed that you opted for the proper GXL wire, most guys don't. Great job!
 
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Discussion Starter #9
Well after reading about the 30mph rollover today, I thought, why not, I can do that too. I had a 26 gallon sprayer in the back, traversing a hill, the sprayer shifted, I tipped, the buggy tipped, and I ended up on the driver side. Broke the tip out windshield and the rear panel of the driver side folding glass window when my shoulder smashed into it and then the ground. Glad I had the winch to get it back over. It was so slow when it happened, I was just crawling, so I think it is ok. She started right up after getting it back to horizontal. Going to change fluids.

ROPS looks ok. Smaller than a 1/8" difference from side to sideround the frame of the windshield. Doors aligned and shut ok on both sides so I may have escaped tragedy. Now to see if I should turn this in to insurance or not.

I have asked toxic for that driver side glass part number. I may take the passenger side off and have one cut. Looks like standard tempered glass the way it broke so maybe I can just go to a glass shop and have it cut.

Front window makes me want to cry. $1200. Ouch.

No good deed goes unpunished.... I had taken the afternoon off to spray wild parsnip at our Gun club. FML

Rob

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That sucks man! But at least you walked away from it.
 
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I was riding around with 600lbs of soil in my bed the other day and I was worried on any slope or side incline I would be tipping just like you did. Looks like I got lucky. Hopefully you can find some cheap replacements for the glass and windshield.
 

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Take heart, Rob - there are two kinds of Polaris riders; ones that have rolled their machines and ones that haven't... YET! Glad you walked away unscathed!
 
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Rob, posted Window part number in other thread.
Glad you are Ok.
 
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Well after reading about the 30mph rollover today, I thought, why not, I can do that too. I had a 26 gallon sprayer in the back, traversing a hill, the sprayer shifted, I tipped, the buggy tipped, and I ended up on the driver side. Broke the tip out windshield and the rear panel of the driver side folding glass window when my shoulder smashed into it and then the ground. Glad I had the winch to get it back over. It was so slow when it happened, I was just crawling, so I think it is ok. She started right up after getting it back to horizontal. Going to change fluids.

ROPS looks ok. Smaller than a 1/8" difference from side to sideround the frame of the windshield. Doors aligned and shut ok on both sides so I may have escaped tragedy. Now to see if I should turn this in to insurance or not.

I have asked toxic for that driver side glass part number. I may take the passenger side off and have one cut. Looks like standard tempered glass the way it broke so maybe I can just go to a glass shop and have it cut.

Front window makes me want to cry. $1200. Ouch.

No good deed goes unpunished.... I had taken the afternoon off to spray wild parsnip at our Gun club. FML

Rob

View attachment 88985
Sorry to hear about your snafu Rob.
I just had to replace my tip out windshield, literally installed it last weekend. Dealer cost is, as you know, $1200 before tax, shipping etc.
I was able to pick mine up at Babbitt's for $1080
delivered. That was paying $250 freight from MI to NV. Use promo code Eddie15 for 15% off.
it automatically added $138 for estimated shipping but I had to pay $100 more.


One more thing, it's a different window. Same part number,Redesigned.
Different handle and latch mechanism (works much better by the way) the hinges now have cams in them so adjustment is done through hinges. For wiper/washer, you have to drill your own holes. Windshield now is prepped for wiper no matter what. Easy install except the new latch, complete pain in the butt.


2016 Mid life crisis
 

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Discussion Starter #15
Rob, posted Window part number in other thread.
Glad you are Ok.
Thank you!

I'm a little sore today. Never really thought about just how bad this could have been for me personally. The doors really saved me. Looking back 15 hrs, I really was lucky.
 

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Discussion Starter #16
Sorry to hear about your snafu Rob.
I just had to replace my tip out windshield, literally installed it last weekend. Dealer cost is, as you know, $1200 before tax, shipping etc.
I was able to pick mine up at Babbitt's for $1080
delivered. That was paying $250 freight from MI to NV. Use promo code Eddie15 for 15% off.
it automatically added $138 for estimated shipping but I had to pay $100 more.


One more thing, it's a different window. Same part number,Redesigned.
Different handle and latch mechanism (works much better by the way) the hinges now have cams in them so adjustment is done through hinges. For wiper/washer, you have to drill your own holes. Windshield now is prepped for wiper no matter what. Easy install except the new latch, complete pain in the butt.


2016 Mid life crisis
Thanks for the link. That feels a little better.
 

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Glad you walked away. Machine can be fixed!
 

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Thanks for the link. That feels a little better.
PM sent Rob.
I will get you some pics of the new windshield. Also I'm pulling my dash apart again to install the 8 pin connectors that just arrived so I'll get you some shots of the brace.
Installing it I've never said the F word so many times in my life.
If available to you, get a child to install the brace. My hands are the size of catchers mits and have no business in that space. I lost 2 pints of blood.


2016 Mid life crisis
 

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Rob, glad your ok! Dave, could you post some pictures of that new design windshield (#2882189)? I have the old part# 2879966 and like it, but got a friend wanting to buy a timeout and if the new design is better I wanna relay that to him. Sorry for the semi thread high jack:)
 

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Rob, your installs look fantastic. Really like your fuse block placement, I wish I would have mounted there. I'll have to move mine if I add wiped/washer down the road. Did you fabricate that bracket yourself? Also like your front light mounting brackets. Is there enough room between the bumper bar and the grill to turn them around the other way so the light would be slightly behind the front of the bumper?
 
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