Hidden EBH Plug

Discussion in 'Gen 2 Prius Accessories & Modifications' started by TheForce, Apr 2, 2008.

  1. TheForce

    TheForce Ron Paul 2012

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    I just had an idea on how I could fix my EBH so the power cable wont fail again. I doubt this idea will work because of the bumper foam but I will give it a shot anyway. So here is my idea.

    I want to use one of those 15A marine plugs that are water tight. I actually all ready bought one. I hate the idea of having a black circle on the front of my bumper so I thought maybe I could put it behind the license plate. What I want to do is to put hinges on the license plate so I could just flip it up when I want to use the EBH. The EBH would go in the center of the license plate area. There is plenty of room on the outside for this but I'm worried about the inside. There is foam behind the bumper cover that may not give me enough room to install the plug. What I'm hoping to do is to maybe cut just enough foam out so the plug will fit into place. To keep the license plate from flapping around I will use some magnets since the license plate is steel. Here is a pic of what I had in mind.

    The seal for the plug is missing in the pic.
    [​IMG]

    This is just one of my Prius projects that I want to do when the temperature warms up.
     
  2. Bear68

    Bear68 Member

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    You shouldn't have too much worry about cutting an opening in the foam. We remove foam from the rear bumper covers on many vehicles to install Park Pilots. (Radar assist for parking, beeps when you get too close to the car behind you)
     
  3. Kremtok

    Kremtok Smug Alert!

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    I'd be very interested to hear how / if this works out for you. Please keep us posted.
     
  4. TheForce

    TheForce Ron Paul 2012

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    Well I have part one finished. I managed to get my license plate on a hinge with magnets holding it shut.

    Some parts needed...
    Brass hinges
    Some special bolts I had laying around. Had to grind two bolts down to attach the license plate to the hinge.
    Magnets from old hard drive
    Glue

    I'll try to explain above each picture.


    Here you can see the brass hinges. The bolt attached to the frame is some kind of flat box top bolt. I had it lying around so I don't know what you would buy at lowes. I had to drill an extra hole in the center of the top hinge for the license plate. I also had to grind down the bolt for the license plate so it would close correctly.
    [​IMG]


    Here is the back of the frame. I glued on some high powered hard drive magnents in the lower corners where the square holes are. I had these laying around also. The gap between the magnet and the plate caused by the frame make the strength of the magnet perfect for keeping the plate secure but easy to flip up.
    [​IMG]


    Here it is installed. It looks stock.
    [​IMG]


    Here it is flipped up.
    [​IMG]


    Here is a quick video of the function of it.
    [ame="http://video.google.com/videoplay?docid=-3823806845226708071"]Hidden Electric Block Heater EBH 2006 Prius[/ame]

    All thats left now is to get that plug installed. I just hope that plug I have will fit. If not I'll have to find something else to use.
     
  5. ericbecky

    ericbecky Hybrid Battery Hero

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    <duplicate post>
     
  6. ericbecky

    ericbecky Hybrid Battery Hero

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    This is an excellent project! It looks great. I hope to see it in person some time.
     
  7. patsparks

    patsparks An Aussie perspective

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    I like it.
    I hope removing some foam doesn't compromise the crash safety of the vehicle.

    Could a person use 1/4 inch gutter bolts
    [​IMG]
    but shorter than this one with dome nuts to reduce the profile of what has to fit inside the hinge?
     
  8. TheForce

    TheForce Ron Paul 2012

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    I think that should work. The bolts I used had the same thread size as the stock bolts. If your planning on doing the same thing you might want to make sure you get the same thread size so you can use the built in nuts. The bolt I used had a pretty flat head. It allowed the hinge to lay parallel to its self. I guess I could still grind this down a little if needed. I had to drill a center hole above where that bolt would be so the plate bolt would not interfere and cause the plate to stick out. I had to do some on the fly engineering to get everything to work right. I'll try to get more detailed pictures when I start to install the plug.
     
  9. Brodie

    Brodie New Member

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    Great idea and looks like it's coming along nicely! I wish I was at all handy.....but I'm not.

    One thing to keep an eye on....those brass hinges in contact with the aluminum license plate will eventually cause corrosion of one or the other....I can't remember which metal will corrode the other but they will, esp in the winter with road salt. Not a catastrophic thing but it would stink to lose your license plate.
     
  10. TheForce

    TheForce Ron Paul 2012

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    My plate is not aluminum. I think its stainless steel. Thats why the magnets pull on the plate. Magnets wont pull aluminum.
     
  11. patsparks

    patsparks An Aussie perspective

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    Magnets won't pull stainless either so it is likely just steel which may rust next to brass.
     
  12. TheForce

    TheForce Ron Paul 2012

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    My bad. I guess my plate it steel then. Must be some good steel because there is not s spec of rust on it. It might be plated with something.
     
  13. Kremtok

    Kremtok Smug Alert!

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    Again, I'm very interested in how this turns out. Just as soon as my EBH arrives, I'll probably use your install method. Please continue to share with us as you continue the project!
     
  14. rmpmd11@verizon.net

    rmpmd11@verizon.net New Member

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    Okay, I give....What is an EBH plug?
     
  15. patsparks

    patsparks An Aussie perspective

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    Electric Block Heater. It pre-warms your engine to prolong the life of the engine and improve fuel consumption. It isn't standard but can be added to a Prius or a conventional vehicle. Most useful in very cold climates.
     
  16. TheForce

    TheForce Ron Paul 2012

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    Well I'm finally finished it. I'm surprised because usually when I do a Project like this I always seem to cut myself and bleed but this time I did not. Instead I'm blessed with blisters on just about every finger. :mad: Oh well on to the good stuff.

    Parts used...
    Weatherproof marine 110v 15A plug.
    Male and female 110v plugs that you can add your own wire to.
    Old heavy computer power supply cable to cut up and use as the extension wires.
    Some small bolts to secure the weatherproof plug to the bumper cover.
    Some black tape to waterproof the connectors.


    I drilled a hole using one of those doorknob hole drill bits. I had to file it down a little to get the plug to slide in the hole. I also used 3 bolts to make sure the plug wont come out of the bumper when I disconnect the power.
    [​IMG]


    Here you can see where I cut out the foam. I cut all the way through it just for the heck of it.
    [​IMG]


    Here you can see the easy disconnect if I or anyone else would have to remove the bumper cover. If I did not put this here it would have been impossible to remove the bumper if needed without cutting the wire. The end that comes from the bumper cover goes down and behind the actual bumper and is zip tied where you see it. Male connector is from the bumper cover and the female is from the EBH.
    [​IMG]


    Here is the plug installed. And yes the magnets still pull the plate shut. :D
    [​IMG]


    Here is what it looks like with the cover removed.
    [​IMG]


    Here it is with the electric hooked into it. First time in a few months that my block heater has had power. Its warm out now so I think I will just give it about an hour of juice before I drive.
    [​IMG]


    Here is what it looks like at rest.
    [​IMG]
     
  17. Rae Vynn

    Rae Vynn Watch out, I have a degree in BS!

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    What is the "thing" that is sticking out of the top of your grill, right in the middle? It LOOKS like a cut cable.
     
  18. TheForce

    TheForce Ron Paul 2012

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  19. Rae Vynn

    Rae Vynn Watch out, I have a degree in BS!

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    Ah, I see. (Or, you do)

    Thanks for the link... I went and peeked at that thread now...

    Have you thought of putting curb feelers on it, too? :D
     
  20. TheForce

    TheForce Ron Paul 2012

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    No I don't need the curb feelers. I know my Prius well enough to know how close I am to the curb but the front end is still a little tricky. :)
     
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