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Picture of Wireless Air Horn
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This instructable is for a Wireless Air Horn. The air horn is a standard 12vdc car air horn and is powered with an 18V cordless drill battery. The air horn is wireless, this is made possible by a wireless winch receiver with a remote control also running on 12vdc. A relay is neccesary so that the fuse on the winch receiver doesn't blow.

All of these components are contained in a medium sized plastic toolbox.

Follow these instructions to make this ear piercing, startling horn, for sporting events or anything you desire.


Materials:

1.       12v Air horn ( any standard car air horn will work)

2.       12v 30 amp automotive relay

3.       Plastic tool box or any box that is suitable of holding everything in a confined area.

4.       12-18v cordless drill battery

5.       Wireless winch remote controller

6.       Plenty of wire

7.       Wire nuts

8.       Electrical tape

9.       ¼” wire  quick disconnects

10.    Variety of nuts and bolts

11.    Velcro

12.    Cable ties

Tools:
• Drill and drill bits
• Wire strippers
• Multi meter
• Soldering iron (optional)
• Adjustable wrench
• Mini clamp
• Screwdriver





 

                                          



 

 
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Step 1: Wire and Mount Horns and Compressor

Using 1/4" female quick connects connect a white wire to the positive end on the compressor and a black wire to the negative end. It should be marked + and - on the bottom.

Drill holes to mount the two horns and compressor using a 1/4" drill bit. Drill two additional holes for the tubing for the horn air supply. Feed the tubing through the holes and attach the two horns to the compressor using the Y extender that is supplied. Using the bolts supplied with the horn kit mount the compressor inside the box and the two horns outside the toolbox, making sure that the lid can close.

Step 2: Prepping and mounting the Receiver

Picture of Prepping and mounting the Receiver
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Open up the Winch receiver to reveal the circuit, using the multimeter find the hot and ground wires. Connect the battery to each wire to find the hot wire, then test the other three wires to find the ground. MAKE sure to clamp down the "IN" button on the remote control or the power will not be flowing and no voltage will be displayed on the multimeter.

In this case the yellow/green wire is hot and the black wire is negative. Remember this for when we connect the wires with the rest of the rig. We are left with two other wires, Blue and Brown, we can ignore the brown wire because that will not be controlling anything in this setup.

Cut the end off the power cord with the five pins on it which would normally connect to the winch, we are then exposed to the four wires that we saw inside the circuit.

Mount receiver inside the box making sure to drill an 1/8" hole for the green antenna wire. It is best to have this wire outside of the box so we will have the best possible reception.

Step 3: Wiring everything together: Part 1

Picture of Wiring everything together: Part 1
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Using a female quick connect, connect a white wire to slot "30" on the relay, then connect the other end of this wire to the yellow/green wire using another female quick connect.

Then connect the black wire from the receiver to the black wire of the battery using a female quick connect.

Next connect the black wire from the compressor to the "85" slot on the relay, connect a third wire so that the black wires coming the compressor, relay, battery and receiver can all be wired to together later.

Step 4: Wiring: Part 2

Picture of Wiring: Part 2
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Now connect a wire going from the blue wire on the receiver to the "86" slot on the relay, I chose a green wire so I could tell the difference from the black and white wires. Connect the relay end with a quick connect and the end that connects to the blue wire with a wire nut.

Connect the white wire from the compressor directly to the "87" slot on the relay.

The relay is ready to be mounted, make sure the wires face up so you have easy access.


 

Step 5: Connecting the Battery

Picture of Connecting the Battery
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Now it is time to get the battery ready for connecting it to the rest of the electrical components.

Remove the battery adapter from the cordless drill that the battery came from and use that to connect the wires to. I resoldered the wires to the battery port to make them more sturdy. On the opposite end of the wires, add MALE quick connects so that they can easily connect to the rest of the setup.

It is also good to have these be able to disconnect if the battery dies, malfunctions, etc. it is easy enough to replace.

Connect the white wire from the battery to the FEMALE quick connect containing the yellow/green wire and the white wire.

Connect the black wire from the battery to the FEMALE quick connect containing the negative wires in the circuit.

Step 6: Clean up

Picture of Clean up
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Organize the wires inside using cable ties and clear a space for the battery. There is no need to secure the battery because it needs to be removed so it can be charged.

Use velcro to hold the remote so it won't be lost.

Add electrical tape to any connections that you deem neccesary.

As you may have noticed there are two buttons on the remote control. "IN" and "OUT" these would be used to control the winch cable, but in this situation we only have the "IN" button connected (blue wire) so the "OUT" button will not do anything when pressed.
                                             
COREYZ 5012 years ago
The relay increases current in the circuit. which is a necessity in an air horn circuit due to the fact that the air compressor requires a large amount of current to work properly. if you would like to you could definitely do it but it will probably sound like crap. i have a dixie air horn that i had installed in my 1997 pontiac bonneville and it made a huge difference.
What's the purpose of the relay in this design ?
Chevybtd052 years ago
I followed your instructions and all, my question is do you have to use the 12-18 volt battery is it recommended because I am using a craftsman 19.2 volt battery the batteries are nearly 9 years old and Idk if its because they were old and just blew or if its because of the battery voltage I'm using?
mammasboy2 years ago
awesome instructable friend :) if only i could afford the parts for it
omnibot2 years ago
Hmm .. a couple of theses hidden around town during a zombie apocalypse could be useful as distractions.
jongscx2 years ago
Hee hee... If there was a "Made from Harbor Freight" contest too... :-D

You could've also made the horns detachable and hid them inside the toolbox for transport.
dbspeedshop2 years ago
Nice Job - I was going to vote for this in the make to learn contest but can't find it. If you add it I will vote. :-)
CarpePM2 years ago
SHUT UP AND TAKE MY MONEY!!! Nice work!