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In this video I make a replacement temperature controller for Oxford heated grips. After having had two controllers fail on me due to corrosion, and replacement units costing nearly as much as a complete set I decided to make my own low budget controller.
To regulate the temperature I bought a Pulse Width Modulator (PWM) motor speed controller. The unit works by continually pulsing current to the output, the duration of on / off pulses is adjusted using a potentiometer. The longer or more frequent the pulses the warmer the grips will feel, the shorter or less frequent the pulses will reduce the period the heating element is active, making them feel cooler to the touch.
I wired a waterproof toggle switch inline with the live power in to turn the grips on and off. The reason I wired it into the live input was to prevent any current the could potentially trickle through the ignition when turned off from passing through the PWM leading to a flat battery or excess wear on the components. I do have the grips wired through a relay to prevent this, but its always better to air on the side of caution. It is also a good idea to wire an inline fuse between the battery and controller if you do not already have one so that excessive current is prevented from running through the board.
I housed the circuit board inside a modified clip lock food container to keep it protected from the elements. As with any electrical components moisture will eventually cause them to fail, so sealing the unit as well as possible it crucial. I did this using an MS Polymer based adhesive because it sticks to almost anything creating a watertight seal that is flexible.
For me this housing was very much a function over form solution, admittedly not as tidy as the original Oxford controller. It came down to needing a housing that was watertight, strong, small enough to fit on the bike and ultimately cheap! I may look into 3D printing a custom enclosure in the future, subscribe to catch that video 
Parts used:
▶︎ 12V-36V Pulse Width PWM DC Motor Speed Regulator Controller Switch 12V 24V 3A – https://goo.gl/wpzMeC
▶︎ On/On Mini Small Toggle Switch + Waterproof Cover Mini Small SPDT 12V – https://goo.gl/j2Hz3h
▶︎ Fantastic Elastic Flexible Glue – https://goo.gl/97e0mT
▶︎ Clip & Close Rectangular Food Container 180ml – https://goo.gl/WhmGwi
▶︎ M3 T-nuts – https://goo.gl/VwXIsn
▶︎ M3 Machine Screws – https://goo.gl/2CmCYf
Post time: Jun-18-2017