Installing a Powerlet outlet

[Dave77459]

Last night I installed a pair of Powerlets on to Roxie. I liked what I saw in this thread, and decided to do it myself. I'd been biding my time, but then I saw an article on a DIY Powerlet to USB Adapter. I wanted the USB adapter to recharge phones, headsets, etc. And with a camping trip coming up, with the need to inflate air mattresses, now was the time!

 

I dealed primarily with BurnsMoto. Stephen Burns has been a joy to deal with. He responded to my questions quickly, and shipped about 5 minutes after I ordered. I ordered on a Friday, and had everything to me by Monday AM. He was missing the Low Profile Adapters, so he went through Powerlet. They screwed up and sent the stuff to him, and he resent it to me.

 

I bought the Powerlet to USB adapter elsewhere, but BurnsMoto now carries it. It is in fact made by NAPA, so it could be widely available.

 

Anyways, here's what I bought....

 

The Powerlet Low Profile Adapter with a 24" lead (x 2), P/N PKT-046-24.

http://farm5.static.flickr.com/4009/4618825544_4868782079.jpg

 

The Powerlet right-angle adapter P/N PPL-004 and the NAPA USB All Weather Power Outlet P/N 782-6003

http://farm4.static.flickr.com/3388/4618824062_5867e11a69.jpg

 

The Powerlet to Cigarette Adapter P/N PAC-012

Like it or not, most doo-dads want cigarette plugs rather than Powerlets.

http://farm5.static.flickr.com/4001/4618825306_638d2bb2a4.jpg

 

 

 

The Install

 

Here is the side cover, basically a plastic filler plate from her left side. The holes are where the passenger floorboard mounts, the small inset is for the screw that holds this piece on, and there are two "bosses" that plug into rubber boots for positioning.

 

I had to drill two holes for the Powerlet.

http://farm5.static.flickr.com/4034/4622257362_06a2dbbfab.jpg

 

Using the step drill, I bored two holes for the low profile Powerlet outlet. The instructions said to use an 11/16" hole saw, but I actually used a step bit. I am glad, because the holes are two steps bigger than 11/16"!

http://farm4.static.flickr.com/3402/4622258072_ca2a109969.jpg

 

 

Here is the Powerlet half way through, showing the rubber gasket.

http://farm5.static.flickr.com/4019/4622258508_7f1a08fa5d.jpg

 

 

The Powerlet seated on the rubber gasket.

http://farm4.static.flickr.com/3319/4621652251_7e194a45ae.jpg

 

On the backside, an aluminum washer is installed, then a brass jam nut is used to tighten it down.

http://farm2.static.flickr.com/1153/4621652551_7bfda7cecb.jpg

 

 

One of the Powerlets installed.

http://farm4.static.flickr.com/3406/4622259406_0c24fb31d8.jpg

 

The backside, showing both Powerlets.

http://farm4.static.flickr.com/3355/4621653059_06024aac0d.jpg

 

The Powerlets are covered with right angled rubber boots on the backside. What a PITA these things are!

http://farm2.static.flickr.com/1163/4622259876_772c54a635.jpg

 

The final off-bike step is to add the white "T" connector. This connects the battery harness to the powerlet. You can see the harness below.

http://farm5.static.flickr.com/4058/4622260160_0300f8343d.jpg

 

(Harness)

http://farm5.static.flickr.com/4009/4618825544_4868782079_m.jpg

 

You can see the cavity that the plastic cover goes over in the right middle, right in front of the drive shaft.

 

Confession time: I misjudged where to drill the holes in the cover. The rear Powerlet conflicts with the large bolt at the back of the cavity. Not much, maybe 1/8". But it is enough to make me want to buy a replacement cover and do it over. Maybe put one outlet on the left side, and another on the right. *sigh*

http://farm5.static.flickr.com/4019/4622262028_c6183f79dd.jpg

 

Here it is installed. Note the power leads coming out at the top.

http://farm2.static.flickr.com/1176/4622262274_d5d7584030.jpg

 

This is how it opens.

http://farm4.static.flickr.com/3386/4622262494_c41d9999ea.jpg

 

Now the right side fuse cover and the passenger floorboards are re-installed. When the floorboards are up, you can hardly see the Powerlets.

 

Note too the coil of wires up top. I lacked a spade connector, so I used the harness as supplied. As a result, there is a vast amount of excess wire at the top, under the seat. I need to fix that soon.

http://farm2.static.flickr.com/1155/4621656099_6302ff4d8f.jpg

 

Job done! Now I can power my auxilliary electronics, like my phone/MP3 player, or an air mattress when I go camping. I can also use it to attach a trickle-charger to keep Roxie's battery charged. I added a pair because I am planning to buy electric clothes, and they'll plug in here.

http://farm5.static.flickr.com/4037/4621656431_334326c902.jpg

 

This was a pretty easy job, aside from the mis-measurement. Having an outlet or two designed for powersports will be a real benefit!

[Kregerdoodle]

looks great Dave, the Power outlets that I bought would not fit there, as they are a double unit and not the type that you bought... I need to look into what you got..

[Dave77459]

looks great Dave, the Power outlets that I bought would not fit there, as they are a double unit and not the type that you bought... I need to look into what you got..

The low-profile Powerlets that I got fit excellently. I kinda wish I had put one on each side now.

[LilBeaver]

Cool!!

 

Looks like a relatively straight forward install.

 

I am curious as to how dry those components will stay. I was talking to another member this last weekend who had installed a cigarete ligher type outlet just to the left rear of the driver seat and said that it was toast after the first rain he rode in.

 

If you end up taking it back apart again anywyas (since you said you might be looking to switch it out for one one each side) you may want to consider putting a little dielectric grease on the inside (rear of the panel) of the rubber cover where the electrical contacts come together or come up with an additional way to seal it up in there - to help protect from corrosion, the elements, etc. Although, now that I am thinking about this, it'll probably stay pretty dry in there anyways - since the OEM main fuse is back there and is fine.

 

Anyhoo, just sharing a thought.

[Dave77459]

Cool!!

 

Looks like a relatively straight forward install.

 

I am curious as to how dry those components will stay. I was talking to another member this last weekend who had installed a cigarete ligher type outlet just to the left rear of the driver seat and said that it was toast after the first rain he rode in.

 

If you end up taking it back apart again anywyas (since you said you might be looking to switch it out for one one each side) you may want to consider putting a little dielectric grease on the inside (rear of the panel) of the rubber cover where the electrical contacts come together or come up with an additional way to seal it up in there - to help protect from corrosion, the elements, etc. Although, now that I am thinking about this, it'll probably stay pretty dry in there anyways - since the OEM main fuse is back there and is fine.

 

Anyhoo, just sharing a thought.

On my RSTD, the OEM fuse is forward, behind the steel side cover. I suspect that is a drier location.

 

I'll bet the cigarette adapter didn't come with the PITA rubber boot. That should keep it dry. Hopefully.

 

There were a couple things I meant to do. One of them is to add a drop of silicone on the brass jam nut as recommended. I think I'll take it off, add the drop of silicone, and the dielectric grease.

 

Ponch told me that I can mix ABS with the PVC cement to make a serviceable patch or even a component. I kept the drill shavings, so maybe I can make a plug for this panel and move the rear plug to the other side. But that would mean wrestling with that rubber boot again...!

 

Dave

[Ponch]

I've heard you can also mix Acetone with ABS shavings to make filler. That would probably be a lot better than the cement.

[Dave77459]

I've heard you can also mix Acetone with ABS shavings to make filler. That would probably be a lot better than the cement.

Ah, I misunderstood what you said. I'm glad you clarified!

 

Dave

[Ponch]

Considering my recent state of mind, I prolly did say that. I know the cement works great for bonding and I have heard the Acetone/ABS dust-shavings works great for filler.

[Dave77459]

I made the Powerlet to USB adapter tonight. It was super easy, but a bit different than the instructions I found. The right angle Powerlet plug that I used was a bit different than the design used, but only modestly so.

 

The resulting adapter easily reaches the saddle bag (a distance of 3" LOL), but could also reach the handle bars to power my GPS if the batteries die.

 

I'm looking forward to being able to listen to my phone playing MP3s all day, without the battery on the phone dying. And I can charge my Scala Rider G4 too.

 

http://farm5.static.flickr.com/4044/4628469150_84462812c5_b.jpg

 

http://farm4.static.flickr.com/3381/4627866495_cacd944e5c_b.jpg

 

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