Waterproof phone charger - GS500F

[J.M.]

My name's Troy McClure.

https://tvmedia.ign.com/tv/image/article/994/994898/4-troy-mcclure-lisa-the-simpson_160_1245105602.jpg

You remember me from many pointless posts such as "fitting an LED inside a rev counter" and "posting pictures of popcorn with absolutely no other input". Today I'm back (unfortunately for you) with my waterproof phone charger, for a Suzuki GS 500 F.

Okay, so obviously I'm not really Troy McClure (sorry to disappoint), but I digress.

With an entire month sitting between me buying the GS and me being able to ride the GS, it gave me ample time to learn a little bit about the bike, fit an alarm and come up with a solution for long distance riding.

I've linked to the thread about the alarm above, this one is about the solution for long distance riding.

I have an Android phone which comes with Google Maps and Navigation. Bundled together it makes a great portable SatNav, with one downside. The battery life on my HTC Wildfire is appalling. That, and I can't see the screen, so I have to listen to directions and pull over whenever I do not understand them so that I can check the map.

My initial thought was the usual "waterproof cigarette lighter socket", but that got me thinking. Yes, the actual socket is waterproof, but what about the in-car charger. Taking the name very literally, they are designed for use in cars; a dry environment. There's no need for it to be waterproof, so why would it be? I want my solution to work in all weathers without having to buy waterproof chargers (which I would guess costs more), so that's exactly what I came up with.

My general thoughts are as follows:
- The battery outputs 12v
- A cigarette lighter socket outputs 12v
- My phone requires 5v to charge
- An in-car charger must logically "step down" the 12v to 5v
- An in-car charger already has the connector I need to charge my phone

Using the above, I guessed that an in-car charger would have a circuit inside that I could steal, then I could simply chop off the charging cable from it.

I could then mount a waterproof male and female connector on the bike somewhere, so that I could simply plug it in and unplug it with ease, like with a cigarette lighter socket.

Anyway, MORE PICTURES some pictures!

https://i1106.photobucket.com/albums/h379/jordanmoore9/Sidney/IMAG0264.jpg
I started off with these components to do the electrical side of things. We've got:
- A very cheap in-car charger (about a quid off of eBay, expect dodgy circuitry)
- Waterproof connectors (designed for LED lighting, I bought 2 of these)
- A standard relay
- A waterproof rocker switch (I decided not to use this, due to lack of mounting options)
- Waterproof inline fuse (even though it's going under the seat)
- Blue Thingy-ma-bobbies (yes, that is their technical name)


https://i1106.photobucket.com/albums/h379/jordanmoore9/Sidney/IMAG0268.jpg
The first real step was to identify a switched live on the bike. Luckily I had gotten fed up whilst fitting my alarm and trailed a switched live cable to the back of the bike, straight from the ignition. The red side is positive, the blue side is negative. The yellow wire is for the remote start.
I cut the switched live in half and incorrectly attached them to the relay. I must stress that I got this step wrong. The switched live did not need cutting, rather I needed to splice it.


https://i1106.photobucket.com/albums/h379/jordanmoore9/Sidney/IMAG0269.jpg
Cracking open the in-car charger, I found exactly what I wanted to find. The fuse sits on the positive wire rather than on the board (easier to replace with my fuse) and there is a circuit in there to do the 12v->5v. On the downside, those wires are shockingly thin and the solder is shockingly rubbish.


https://i1106.photobucket.com/albums/h379/jordanmoore9/Sidney/IMAG0270.jpg
A nice picture of the circuit dangling from the inline fuse's wire. Soldering that was a pain, it really was.


https://i1106.photobucket.com/albums/h379/jordanmoore9/Sidney/IMAG0272.jpg
I cut up the original case for the in-car charger to protect the circuit. Wrapped it in electrical tape to help keep the water out and then used a small knife to make the LED visible. This photo is slightly out of order because I had already connected it to the relay at this stage, obviously. Unfortunately, I seem to have lost those photos.


https://i1106.photobucket.com/albums/h379/jordanmoore9/Sidney/IMAG0299.jpg
The finished product looked something like above though. Quite tidy and the seat still fits on snugly without crushing anything.


Coming out of the in-car charger there were also another 2 wires. These wires are obviously the positive and negative wires for actually charging the phone. I've ran these to the front of the bike with the original wiring loom. Under the tank, through the original zip-ties, etc.


https://i1106.photobucket.com/albums/h379/jordanmoore9/Sidney/IMAG0297.jpg
The connector (female) basically comes out just underneath the clocks, using one of the bike's original wire-hooks to keep it in place.
The black cap on the top is self-made. To make it I used the cap (which has a hole in) from the 2nd set of connectors and covered the bugger in glue. A lot of glue. I kept layering up the glue until there was a nice firm top which wouldn't pierce easily. I then sprayed it black.


https://i1106.photobucket.com/albums/h379/jordanmoore9/Sidney/IMAG0296.jpg
I forgot to mention, with the chopped off part of the in-car charger, I made what's pictured above with the other half of the connector (the male side). I didn't like the clear wire cover, and I was too lazy to spray it, so I covered the thing in black electrical tape. Sorted.


https://i1106.photobucket.com/albums/h379/jordanmoore9/Sidney/IMAG0295.jpg
When I want to plug in the phone, it simply pushed together like above. Then there's a cap which screws over it to help ensure a water-tight connection.


https://i1106.photobucket.com/albums/h379/jordanmoore9/Sidney/IMAG0294.jpg
I run the cable through the handle bars, to ensure that it doesn't come loose or get in my way, and to ensure that it is in a good position to charge my phone.
Mounted is also the bracket for my waterproof phone case. That required a lot of work to make it fit. It unfortunately had to be all done with a file as well, because all of my hacksaw blades are blunt. Well, until I got fed up and borrowed a friend's angle grinder that is.


https://i1106.photobucket.com/albums/h379/jordanmoore9/Sidney/IMAG0293.jpg
With the phone case on, it looks like above. The case is clear of the tank, easily visible, you have access to the keys, good view of the clocks, etc. Unfortunately I had to cut a hole for the phone charger cable to fit through - but that shouldn't really affect it too much.
I would have put the phone in the case, but I was using the phone to take the photos. It's a nice and secure fit though.


https://i1106.photobucket.com/albums/h379/jordanmoore9/Sidney/IMAG0298.jpg
When you're not using it, the whole thing is barely visible. Given an Allen key as well, you can remove the bracket in about 20 seconds. I'm keeping it there permanently though.


https://i1106.photobucket.com/albums/h379/jordanmoore9/Sidney/IMAG0303.jpg
It all manages to tuck nicely under the seat as well, using my (mainly) oxford tool kit to securely pack it in to place. They're not moving any time soon. Having it all under my seat and the bracket permanently mounted is an ideal solution for me because it means if I'm ever lost, I can get home.


I think that's all. So like.. bye.. and stuff.
____________________
2004 R1 & 2018 XSR900

[bobert]

that is AMAZING lol


want want want
____________________
........FOUR WHEELS MOVES THE BODY, TWO WHEELS MOVES THE SOUL........

[sidewinder]

Nice job there buddy

[salty21]

link fail^^

can you please fix it as i like the idea of this but cant be arsed to make one
____________________
04 NSR 125(sold) ---- 03 CBR 600rr(sold) ----90 pan euro ST1100 '' ----02 CG 125
94 CB400 Super Four ---- 2000 VTR SP1 (sold) ---- 08 ninja p8f(sold, meh) ----05 CBR600rr

[J.M.]

Thanks guys

[sidewinder]

[J.M.]

Sod it, enough with the bodge jobs, I'm doing this properly!

This arrived today:
https://i1106.photobucket.com/albums/h379/jordanmoore9/Sidney/IMAG0402.jpg

Quickly hooked it up to a 12v power source (thank you bike charger!):
https://i1106.photobucket.com/albums/h379/jordanmoore9/Sidney/IMAG0406.jpg

Seems to be putting out 5v like advertised:
https://i1106.photobucket.com/albums/h379/jordanmoore9/Sidney/IMAG0410.jpg

Now just to wait until next week sometime for my wire (10M of the stuff!) to arrive and I can get rid of all my bodge job wiring and do it all properly! I'll also check out what's up with my reserve tank whilst I'm doing all of that.
____________________
2004 R1 & 2018 XSR900

[smegballs]

[J.M.]