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.
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
12. Cable ties
• Drill and drill bits
• Wire strippers
• Multi meter
• Soldering iron (optional)
• Adjustable wrench
• Mini clamp
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
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
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
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
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
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.
Fourth Prize in the
Make-to-Learn Youth Contest