$35.00 Heated Jacket Liner (DIY)

Discussion in 'Equipment' started by 65 Flathead, Oct 10, 2009.

  1. 65 Flathead

    65 Flathead Been here awhile

    Joined:
    Oct 3, 2009
    Oddometer:
    102
    Location:
    Central Louisiana
    NOTE: I have postd the Heated Glove build on page 4 of this thread.:freaky


    (Original)
    Ok, so I had my finger on the button last weekend, the “Confirm Order” button. I had decided on a Gerbings heated jacket liner and T5 gloves. I had to look at the competitors one more time, then read a few more reviews, and, well you know the story. 5 hundred bucks ain’t no chump change to me! Well, I studied it so much that I realized, hell, I can build all of that! So here goes…

    I found this wire on an ADV Rider post. It’s .30 AWG with a high temp silicon coating. They call it “hook-up wire” (Hook a brother UP). I found it here http://www.mouser.com/Wire-Cable/Wire-Single-Conductor/_/N-5ggs?Keyword=83000&FS=True It’s made by Belden, PN 83000-???.
    ??? represents color.
    I ordered a 100 foot roll for 25 bucks, plus 6 something for shipping. Living here in Bum Stuck Central Louisiana, there’s not a lot of outlets for this type of thing. I went to Wally world and bought a nylon workout jacket. Really thin, and with a mesh liner, Perfect! The wire came in yesterday so with torrential downpours not making my scheduled ride out west look too appealing, I went to work.

    I started everything in the right corner. I meant to start in the left corner, but I got dyslexic when I turned everything inside out.

    [​IMG]

    I found a couple of conflicting wire resistance charts, giving 30 AWG between .103 - .105 ohms / ft. Wanting to be more precise, I thought “Hey, I have a hundred feet of the stuff, I’ll check it myself. I came up with .109, stupidly forgetting the impedance factor of 100’ of wire being wound up in a 2” coil. Well, anyway…I’ll spare you all the gory details and fancy pants mathematics of it all (unless you really want it, and I’ll post) but to give me the 80 watts of heat I wanted (3 more than Gerbins) I decided on 2 forty foot sections hooked in parallel. This made routing easier because pulling anymore and I would have given up. For anyone out there with ADD, don't even start this project, just run around thinking about it all day!

    Here’s the first section installed.

    [​IMG]
    I ran the strands about two inches apart in the body, and six strands down each arm. On the far side (from the power cable) I ran one strand though the collar, and down by the zipper back to the power connection.

    Helpful hint* If you have one of those friends that majored in underwater basket weaving, employ their skills at all costs. This is some tedious crap. After the first side was complete, I was done. As a reward, I went and bought a bottle of rum and made myself Fru Fru drinks the rest of the night.

    [​IMG]

    This morning I got up early planning on riding to Monroe and Shreveport to hunt a new modular helmet, but the Fru Fru drinks still hadn’t completely left my system so I went back to work on the liner.

    Here she is all wired up (Almost)

    [​IMG]

    On this section, I ran 2 strands though the collar (making 3 total). The collar doesn’t fit too snug, but I’m thinking of putting some Velcro on it.

    I put it on and plugged it in to my bike. 5 amps, perfect! He bile was only idling, and running around 13.8 volts.

    [​IMG]

    The jacket heated up nicely, and the collar felt like a heating pad on my neck. This is going to be SWEET!!!

    I soldered everything together and sewed / hot glued the main power cord to the hem of the liner.

    [​IMG]

    All there is left is run the wires for the gloves (next thread) and build the controller.

    And here she is!!!

    [​IMG]
    #1
  2. nigelcorn

    nigelcorn Wannabe.

    Joined:
    Aug 17, 2007
    Oddometer:
    815
    Location:
    Henderson, NV
    That is awesome, nice work.
    #2
  3. TheMan

    TheMan Been here awhile

    Joined:
    Dec 16, 2005
    Oddometer:
    160
    Location:
    Hudson Valley NY
    Looks good! How does it work? Got any comparison to a Gerbing?
    #3
  4. 65 Flathead

    65 Flathead Been here awhile

    Joined:
    Oct 3, 2009
    Oddometer:
    102
    Location:
    Central Louisiana
    It hasn't been cold enough here to give it an actual test run, but when I turn it on, even at 70 dgee ambint temp, i can feel immediate heat.

    I've never seen a Gerbing in person, but they advertise 77 wats, mine's 80.
    #4
  5. 12voltclothing

    12voltclothing Banned

    Joined:
    Sep 6, 2009
    Oddometer:
    130
    Location:
    Mpls Mn
    Use coax connectors on your gear. More efficent than SAE connectors

    Depending on how they rate their gear, Gerbings are only 70 watt liners
    #5
  6. router.exe

    router.exe Been here awhile

    Joined:
    Oct 23, 2006
    Oddometer:
    222
    Location:
    seattle, WA
    nicely done!
    #6
  7. 65 Flathead

    65 Flathead Been here awhile

    Joined:
    Oct 3, 2009
    Oddometer:
    102
    Location:
    Central Louisiana
    That's exactly what I had planned. I was leaning towards Gerbins liner ONLY because of the lifetime warranty, but I was going to buy your heat troller, because I figured if it is good enough for the others to copy it, then I'd go with the original. I have been thinking abou heated gear for years now and had thouht of using a PWM setup eeven before I knew that they were in use for this. But, since I'm oing cheap, I'll build that too. There are some preassymbled for 20 bucks, but they're 555 timer based, and it has always been my expriance that the 555 gets squirely when ambiant temp changes. I'm thinking more of a duel op amp type setup.

    By the way, in case I decide to go with your gear in the future, I want to be compatible. What size are the coax connectors?
    #7
  8. trumpet

    trumpet Group W Bench

    Joined:
    Aug 2, 2008
    Oddometer:
    1,472
    Location:
    Connecticut
    The troller I've been using for the past 10 years is 555 based and other than popping the driver mosfet has given no trouble.

    The mosfets heatsink planes underneath the 555 and helps stabilize things. Probably $20 in parts and can be built on perf board and a RS project enclosure.

    I can post some pics tomorrow if that'll help.
    #8
  9. 65 Flathead

    65 Flathead Been here awhile

    Joined:
    Oct 3, 2009
    Oddometer:
    102
    Location:
    Central Louisiana
    I hadn't thought of it like that. The 20 buck version would certainly be less time consumiing. Pics, yes please!
    #9
  10. GalenEvans

    GalenEvans Adventurous Spirit

    Joined:
    Sep 22, 2009
    Oddometer:
    3
    5.5mm X 2.5mm jacks. Plugs are 5.5 X 2.5 x 12mm long.
    #10
  11. BuddingGeezer

    BuddingGeezer Been here awhile

    Joined:
    Aug 17, 2009
    Oddometer:
    233
    Location:
    Benton, AR
    I built one 3 years ago and just redid it last week into a jacket similar to the one shown. I turn mine inside out to keep the outer wires from contacting me. I have ridden for hours at 30 degrees F comfortably and for 1 hour at 14 degrees F and stayed warm.

    I see the wires in the pic cross the shoulder blades. Your shoulder blades have very little fat (insulation) on them and it can get uncomfortable in a hurry with the wattage 30' of 30AWG wire provides.

    Ralph Sims
    #11
  12. tslewisz

    tslewisz Long timer

    Joined:
    Oct 11, 2005
    Oddometer:
    2,382
    Location:
    Bloomington, IL
    About how many feet of wire did you use? I see BuddingGeezer uses 30'.

    Would just wiring it into a Powerlet get too danged hot?
    #12
  13. 65 Flathead

    65 Flathead Been here awhile

    Joined:
    Oct 3, 2009
    Oddometer:
    102
    Location:
    Central Louisiana
    30 ft gives about 52 watts, and I am SUPER cold natured so I was afraid that I couldn't get the coverage with one strand @30 ft.

    For max coverage and to get my resistance right, I used 2 runs of 40 feet and then wired them in paralell. The wire has a resistance of 0.105 onms / ft. 40 feet gives me 4.2 ohms an 39 watts at 12.8 volts. When you put two of these 40 ft strands in parallel, you get a totla resistance of 2.1 ohms, and 80 watts. So all together there is 80 ft of wire in the jacket.

    Yes
    #13
  14. papaduc

    papaduc Been here awhile

    Joined:
    Dec 1, 2002
    Oddometer:
    386
    Location:
    Beaverton Oregon
    I had a Gerbings controller go T/U recently. The controller is about 8 years old so no warranty. I was thinking about making one, if you have some info and pics you could share that would be very helpfull.
    #14
  15. 65 Flathead

    65 Flathead Been here awhile

    Joined:
    Oct 3, 2009
    Oddometer:
    102
    Location:
    Central Louisiana
    Actually, I think this is an optical illusion because of the jacket being inside out in the photo. While reaserching for the build, I had read an article warning against this, so I didn't run any wire over the boney parts of the shoulder.
    #15
  16. Gizmo

    Gizmo Hermes

    Joined:
    Apr 10, 2003
    Oddometer:
    1,668
    Location:
    Phoenix, AZ
    Great work! Looks like it will work just fine.
    #16
  17. Motoriley

    Motoriley Even my posing is virtual

    Joined:
    Feb 14, 2003
    Oddometer:
    2,686
    Location:
    Deepest darkest burbs of Montreal
    I'm a little confused....(happens easily)....is this special wire or just regular copper?
    #17
  18. 65 Flathead

    65 Flathead Been here awhile

    Joined:
    Oct 3, 2009
    Oddometer:
    102
    Location:
    Central Louisiana
    I put the link to where I got it at the start of this thread. I tried finding a data sheet on it, but Beldin's link is no good. It seems to be copper with a plating of somesort. The insulation is a high temp silicon based and so far I've found nthing that'll stick to it. I got the wire specs here http://www.advrider.com/forums/showthread.php?t=113134
    and figured there was no sence reinventing th wheel. If it worked for them, it'll wok for me.

    The wire is very flexable, thin, and seems pretty tough. I'm wiring a set of gloves now, and I have to wrap the end around a homemade croche hook to pull it through. It can stand quite a few wrapping and unwrappings before I starting to break, so hopefully it'll last for several years. I am carefull not to put any sharp bends anywhere, and left a little slack all round to minimize physical stress on the wire.
    #18
  19. trumpet

    trumpet Group W Bench

    Joined:
    Aug 2, 2008
    Oddometer:
    1,472
    Location:
    Connecticut
    [​IMG]
    [​IMG]
    [​IMG]

    10K pot linear
    555
    rfp50n06
    1n4004
    330K
    2.2k
    1.2k
    100ohm
    .047
    x16g700 self reseting fuse
    2x 105 ceramics

    I'll draw it out later and post a schematic
    #19
  20. Motodisiac

    Motodisiac Moto Terrorist

    Joined:
    Jan 13, 2006
    Oddometer:
    3,523
    Location:
    City Of Angels
    This is nice, for some reason I always thought heated jackets have way more complicated technology. How much does it weigh? Have you thought about building it straight into the jacket?
    #20