Chris's Navara Tail Lights

 Chris has a Nissan Navara and he is building his own Tray back.
I am helping out with the tail lights.

New lights are:
https://www.ozled.com.au/led3852-kits
https://ledautolamps.com/combination-lamps/685-3852-series.html?search_query=3852&results=1

U1/218 Leitchs Rd, Brendale QLD 4500
07 3205 4355 sales@ozled.com.au

 

LOAD RESISTORS
Apparently LED lights require a load resistor

6 Ohms across each circuit.  These are not current limiting resistors.  These resistors simply get hot.  Very hot.  As I understand it, Australian design rules have some requirements in regard to vehicles detecting blown bulbs and they do this by measuring current.  These resistors apparently simulate bulbs. When we have more time, I will experiment to work out whether all circuits need resistors.

DEUTSCH CONNECTORS

Jaycar have a set of instructions for assembly
https://www.jaycar.com.au/medias/sys_master/root/9218268004382/Primer-DeutschPlugConnectionGuide-Jaycar.pdf

  

RESEARCH ON LEDS
https://www.newd-max.net/viewtopic.php?f=17&t=1272&sid=336bc99c2be1af50a332894625eec2f6&start=1c

DMAX Plugs cut off the vehicle wiring harness and we replaced with Deutsch.  If I was doing it again, I would use Molex so I could parallel up the wires for the load resistors.

Brown = Tail
Red=Brake
Yellow or green is the indicator.
Black is GND in the corner.  We used white

Clamped the resistors between two pieces of DIN rail.

I made this tool by grinding down a small scred driver and then using a hacksaw and file to cut the groove.  The back of the screwdriver was ground down too to make it thinner to fit in the slot.

Once the green bit has been removed, the plastic retainer is pushed aside, can use a small flat blade screwdriver for this.  Then pull the wire from the back.

Finally!

THE PROBLEM 

The lights are not retained well in the housing.  There are quire small and shallow click in bits.  Out bush, Chris did a temporary repair by strapping them all together with cable ties.  Now I am re doing it, it would be nice to do a more discrete fix.
Ideas for now are:
a) Put some very small self tappers in.  Down side is we do not know what we might screw into.
b) Glue - Possibly 3M 8005 which can glue polyethylene and presumably other plastics which don't seem to be able to be glued by many glues.  

 

 

I drilled 2mm holes.  It's a free gap behind so no risk of drilling into anything important.

I used 4g x 1/4 stainless screws.  4g is an American size I believe.  Because we had those. 

There are 3 holes.
Top holes - not used.
Middle holes used for the lights.  6mm Bolts.
Bottom holes have M5 Countersunk for the load resistor plate. 

The "finished" job.  Tail lights only.  The number plate lights were taped on because we did not have new lights.

Rear view showing the resistor plate

I used this tool to crimp the Deutsch connectors 

We have the genuine Deutsch crimp tools but the pins supplied by Jaycar are different.