OPS Relay Mod. Slightly different

[Burning oil]

I hate cutting an original wire harness and go out of my way to prevent it. I am not aware of any mates/connector that will allow OPS connector to plug into it. So, I made my own with an old OPS.

Used a tubing cutter to cut the body off cleanly.


The middle pin stayed attached so I cut it off down low with lots of pin to work with. The two outer pins will stay in the body. You need to grab them down low from the connector side and push them out. Be carefull not to bend them.


Soldered 16 gauge wire to the tips of the rear. Make sure you attach and solder it like show or the pin will not fit back into the body.


Wires with pins reinstalled.


I used "Goop" brand sealant to pot the wire inplace. If you use Goop only apply 3/8" or less and let that dry then come back with another layer, and so on until you have covered/insulated the pins/wires.


More to come in just a minute Have to upload the pictures.

 

[Burning oil]

Once I had the old OPS body finished I made up a little harness. This harness looks factory and it is plug and play. You literaly unplug your OPS connector plug it into the modified OPS body. Then plug the new OPS connector on the harness into your existing OPS.
You can get the old OPS and the connector at any junk yard. You will need the connector to build the harness.
The relay is the weather pac/sealed type and does have the diode.



Upper connector from OPS cut at junk yard.
Lower connector is the old modified OPS.






The black one is the modified OPS body. They grey is the new. All it does now is send a signal to the oil gauge and 12v signal to relay. The grey wire is now the signal wire to the relay.


Just another picture.


All finished up. The green wire you see coming out of the relay cover could be used to power on the LP anytime 12v is applied to it. Im still looking for a cool switch and location for it.
This relay mod did not incorperate the WTS/glow plug priming of the LP. My truck starts just fine so opted not to install it.

 

[NVW]

Looks good.

 

[Burning oil]

Thanks Leo. I like that if for some reason the relay fails (not likely) I could just plug the original harness back in and run of the OPS again.

 

[DieselSlug]

Very cool.. I still need to do the OPS mod...

 

[3500GMC]

Aren't you a crafty little booger...

Looks good.

 

[Burning oil]

I read a book once on how to solder
:ciappa:
:fing02:

Just had to get my thumb outa my butt and do it.

 

[WarWagon]

Get a borg-warner OPS as they come apart easy - the body will just pull off the sender as they are pressed on with an oring and plastic notches to hold them on.

 

[JiFaire]

Very cool, Leroy! I also like the idea of not messing with the wiring and having the option to 'go stock', as it were...

You thinking of adding this little beauty to your list of handy items to buy? (for the less DIY-inclined?)

 

[buddy]

I was thinking this could be an easy enough product, even with the dual relay option I put up. But would need the harnesses, that like you say aren't available.

 

[Burning oil]

Get a borg-warner OPS as they come apart easy - the body will just pull off the sender as they are pressed on with an oring and plastic notches to hold them on.

Mine was a BW too. It had more of a rolled lip that would have made it much harder to remove than just cuting the body.
Got a picture of yours? might help the pepole looking find one in the junk yards.

Very cool, Leroy! I also like the idea of not messing with the wiring and having the option to 'go stock', as it were...

You thinking of adding this little beauty to your list of handy items to buy? (for the less DIY-inclined?)

Not to interested in offering it unless there is a big demand. It would be time consuming to round up a bunch of old OPS to make up the harness not to mention the labor. I know people that could make these connectors in an injection moulding machine, but would have make thousands of them.

I was thinking this could be an easy enough product, even with the dual relay option I put up. But would need the harnesses, that like you say aren't available.

You might look into it. I seem to remember when doing the DS4 to DB2 convertion that there is an extra pin/termenal not used on the GP relay that might make a convenient signal to the relay. But, I can't remember if that slot was unused on the DB2 or DS4 GP relay.