Reply With QuoteOriginally Posted by travelrover
I can’t find the fitting instructions from mine. There is lots oF info re installs on the forum. Here are some notes I did save from Rob when mine was getting done. Hope it helps
Ex bOx tips
A few handy things to know when installing the Ex-Box...in a roughly-chronological order:
1) This is much easier with two people unless you already really know your way around the Defender. I'm pretty new so having a mate with me to run ideas past and for poking and pulling and wiggling wires and bashing things was a big help.
2) It's all pretty straightforward and methodical, but some things can be daunting. For me, removing the plates that the relays are currently mounted on was a bit scary. They required a good bashing with a screwdriver and hammer. I was pretty glad Daniel was there to show me first and tell me how people hate doing that part!
3) Before removing the fuse box and relays from under the driver's seat, take a couple of photos first, just so you know where they all go back to once they're in the Ex-Box.
4) When pushing the wires out of the driver's seat space and into the space above the transfer box, make sure nothing is too tight...and be really careful of cable ties that may restrict the loom. I cut my cable ties then put new ones on afterwards. This really helped with the tension on the loom.
A good tip here is that when you remove the power cable from its conduit and put it in with the main wires going into the Ex-Box, re-use the discarded conduit for the poor old central locking cable that will still reside under the driver's backside, all on its own. This will help protect the cable.
5) When removing the existing plate that sits under the cubby box, definitely rivet the two fuel line brackets before undoing the bolts. I know it doesn't appear on the instructions and that some people have suggested doing it, including Daniel, but to me this is a no-brainer as it makes life easier and only takes 2 minutes to do.
6) When retrieving the central locking wire back through the grommet, there are two ways to do this. Either take off the white connector and put it on again afterwards, or get two long screwdrivers and a ham-fisted Queenslander and poke and wiggle it through taking GREAT CARE not to damage the other wires. it can be like spaghetti junction in there so this requires patience! When pushing the wires up into the Ex-Box, push through the big relays first...and hold them out of the way while you poke the others through. This is when it's awesome having a second pair of hands.
7) When they're all through and it's time to bring the rubber grommet up from beneath the car and into the Ex-Box through the hole, pull it through a bit at a time, wiggling it upwards until it seats in place. Maybe use a screwdriver to help. Do NOT do what I did and pull it all the way through and then try to push the collar of it back through - the hole is 2mm in diameter too small to allow this to seat properly. Daniel helped here and solved the problem in a matter of seconds by starting again.
8) Heatshield. Do it. Attach to the bottom of the Ex-Box using rivets....or if you have the softer stuff, I guess an adhesive might do the trick.
9) The bolts that held the plate on under the cubby box may be a bit short...so you might need to just put plenty of pressure on the box to get the nut to "bite" and screw on....but it will go down. Be firm with it.
10) Make sure everything is nice and sealed - with sikaflex and/ or neoprene tape.
As I already had my UHF installed and fitted to the cubby box, this could have caused issues with opening the box so I pulled the power and aerial cables through more and then wrapped them up in a conduit.
Also, just to be tidy(ish) I got some carpet from Bunnings and cut it to fit the rest of the box. Looks smarter and will be kinder to my phone should I keep it in there.
Sorry I didn't take pics of me actually doing the install. I got a bit carried away and didn't think to stop. Very naughty of me, I apologise.
I hope these comments help. Happy to elaborate further if it's helpful. PM me if you like.
Love the Ex-Box...it's a great bit of kit. Thoughtfully designed and manufactured too. I'm seriously impressed. Well done Daniel...and thank you again for your help.
Rob
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