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View Full Version : DIY: Putting AIRHORNS in a JAZZ!!! 56kb WARNING



petrovski
07-07-2004, 12:28 PM
Disclaimer: The following is provided as a GUIDE ONLY, and neither myself nor Ozhonda take any responsibility for the outcomes of someone else doing the following. You follow these steps at your own risk!

Aim:
To put a 3 horn airhorn setup in a jazz to replace the standard horn.

Required:
- 3 horn airhorn kit (from autoone about $45-50)
- 3m of red electrical wire
- 1 metre of black electrical wire
- 20 amp fuse and in line fuse holder
- Wire connectors (circle ones, plug ones and the ones to join two wires together)
- Wire cutter/stripper
- Electrical tape
- Car jack
- Flathead and Phillips screwdrivers
- Socket wrench with 10mm, 12mm and 13mm sockets (there maybe other sizes needed)
- 25cm by 25cm (or 20x20 - i cant remember, however it is about that size) angle bracket (L shape, not a triangle one)
- Approximately 30mmx8mm (or 9mm) nut and bolt (size is up to you)
- Drill
- Metal file
- Hacksaw
- about 8 hours (4 or 5 hours will be spent customising the bracket.

Steps:

1)
If you have a front spoiler (as on the VTI-S) you will need to remove that first. Its 2 screws and about 5 or 7 bolts. Can be undone with a socket wrench. WARNING: Be careful that the clips that hold the bolts dont fall out and if they move you can just slide them back in place with a screwdriver or pliers.

2)
On the FRONT DRIVERS SIDE loosen the wheel nuts on the wheel, jack up the car and then take the wheel nuts off and then remove the wheel (a certain person jacked up the car only realising that he forgot to loosen the wheel nuts first)

3)
The following picture is under the front drivers side in FRONT of the wheel arch. Here you have to undo the screw and and remove the tab which can be done with a flathead screwdriver (If you're unsure how to undo the tab see the jazz owners manual).
http://tech.ozhonda.com/diy/air_horn/guard%20tab%20and%20screw%20below%20red%20%20%20%2 0circles.jpg

Inside the wheel guard there are more tabs you have to undo. See the two pictures below.
http://tech.ozhonda.com/diy/air_horn/guard%20tabs%202%20red%20circle.jpg
http://tech.ozhonda.com/diy/air_horn/guard%20tabs%20red%20circle.jpg

Once you have undone these you can now pull back the wheel guard. You might need to use a little force but it will come out. See the pic below.
http://tech.ozhonda.com/diy/air_horn/pull%20back%20guard.jpg

also too if you need mor information about removing the tabs see in the owners manual what tabs to remove when you want to change a headlight globe.

4)
The horn is a little black cylindrical thing with a single black tube running to it - you can't miss it! It is mounted to a gold L braket. You have to ubolt the bracket. DO NOT THROW OUT THE BOLT!! Next undo the wire by the black clip. Once this is done undo the horn from the L bracket. This too requires some force but it will come undone. DO NOT THROW OUT THE BRACKET!! just redo the bolt back into the horn and keep it somewhere if you ever want to use the original horn again.

5)
Here comes the very slow process of getting everything to fit. I've drawn up 2 diagrams to help.
http://tech.ozhonda.com/diy/air_horn/airhorn%20setup%20side%20on.jpg
http://tech.ozhonda.com/diy/air_horn/airhorn%20setup.jpg

The Compressor
In the first picture the black bracket at the top is the mounting point for the L bracket for the original horn. The first bit is the easiest which is making the compressor part of the airhorn fit. The original horn L bracket has a long side and a short side - you mount the compressor to the short side of the original L brakcet and the long side to the black mounting point. The airhorn kit comes wiht the bolt to mount the compressor to the bracket. Also, have the side where the wires attach to the compressor facing the rear of the car! Basically just like in the second picture. you can also see on the left of the picture how the compressor is mounted
http://tech.ozhonda.com/diy/air_horn/bracket%20behind%20mounting%20point.jpg

My Bracket and the Horns
In the second picture with the horns, all the bolts, nuts and little grey brackets and the horns come in the kit! The only thing that does not come in the kit is the bracket i made!!!

The 25x25 bracket is goin to need drilling, cutting and filing!!

IMPORTANT NOTE: You need to make your own judgements of where to drill and where to cut by mounting the horns and putting the bracket in seeing how it fits take it out adjust it and do it all again over and over to figure out exactly where to cut and where to drill so it will fit. ALSO DONT FORGET THAT IT HAS TO FIT INSIDE THE WHEEL GUARD AS WELL - MY GUARDS ONLY SLIGHTLY TOUCH THE BACK OF THE HORNS SO IT DOES FIT BUT IT IS VERY CLOSE SO YOU HAVE TO BE CAREFULL WHERE YOU CUT AND DRILL

what you need to do is pick a side that you want to mount the horns on and the side that will mount to the mounting point.

with the side that you are going to put the horns on you may need to drill more holes or you may need to drill the holes bigger or you may need to cut a little bit off the end so it will fit in length ways. IT DEPENDS ON THE BRACKET YOU BUY!! In my case i needed to drill an extra hole for the middle horn and bent the bracket to the left so the length of the horns will fit in. REMEBER THE FRONT BUMPER IS CURVED SO THE LARGE HORN WILL NOT FIT ON THE SIDE THAT IS SHORTER! AS WELL ON THE SIDE THAT IS MOUNTING TO THE MOUNTING POINT - HOLD THAT BACK FROM THE MOUNTING POINT SO THE HORNS WILL FIT - WILL DEAL WIHT THIS NEXT. I also needed to drill bigger holes to accomodate the bolts that held the individual horn brackets.

Once that is done take the horns off the bracket again the side that will mount to the mounting point will have to be cut in about half or a little bit less. On the bit that is cut off drill holes in either end. One end to attach to the bracket you are making and the other to attach to the mounting point (in black at the top right of the first picture in step 5). Now drill a hole in the bracket so you can attach the piece you cut off with a bolt that you provide - as in the first picture. It can also be seen here
http://tech.ozhonda.com/diy/air_horn/bracket%20behind%20mounting%20point.jpg


Now that the bracket is together can mount your horns and hold the compressor braket next to you bracket and figure out where to run the air tubes.

once this is done cut the tubing to fit form the horns to the compressor - use as short a tube as possible but BE CAREFUL NO TO CUT TO SHORT BECAUSE YOU ONLY GET ENOUGH TUBE TO DO THE JOB.

you can now bolt it all in to see that it all fits in together as in the second picture in step 5. You use the original bolt and it is long enough to hold the two brackets in together. This is what it looks like where to mount it
http://tech.ozhonda.com/diy/air_horn/bracket%202%20mounting%20point.jpg
To be sure it fits put the guard back up and all the tabs and screw in so see whether or not the guard can fit back in!!!!

6)
Once eveything fits - its time to do the wiring :) on the airhorn pack i got use the TOP diagram on the back of the packet as a guide.
unbolt the horns again. You should get a relay in the airhorn pack. i cable tied the relay to the end of the braket as in the second picture in step 5.
attach the red wire to the inline fuse holder and the inline fuse holder will attach to the battery positive terminal (use the wire joiners). DO NOT PUT THE FUSE IN YET!
you will need to run the wire like in the following diagrams form the battery to the relay. The diagram on the back of the airhorn packet will tell you where to attach the wires.

http://tech.ozhonda.com/diy/air_horn/fuse%20holder.jpg
http://tech.ozhonda.com/diy/air_horn/airhorns%20wire%201.jpg
http://tech.ozhonda.com/diy/air_horn/airhorns%20wire%202.jpg
http://tech.ozhonda.com/diy/air_horn/airhorns%20wire%20through%20hole%20behind%20%20%20 %20light.jpg

next is the earth wire which attaches from the relay to the chasis. I did it like the picture below.
http://tech.ozhonda.com/diy/air_horn/earth%20wire.jpg

i think from memory the negative on the compressor needs to attach to an earth as well and the positive from the compressor attaches to the relay and the original horn wire attaches to the relay as well. Now that it is all wired up put in the 20a fuse and press the horn button to see if it works. If it does mount it all back in and reverse the steps 3 to 1 and you are DONE.

this is the finished project
http://tech.ozhonda.com/diy/air_horn/airhorns%20finished.jpg


Comments
I would like to thank Wynode firstly for hosting all the pictures for me.
There is also a 2 horn setup which i think personally would be a much easier setup to fit in!!!!

If anything is unclear or i havent explained anything well enough or it doesnt make sense or anything pm me and ill fix up the post or pm you back

Pete :)

wynode
07-07-2004, 10:48 PM
Pete......that's a great write up! Why can't others follow in your footsteps?

Would mind a few of those in my car hehe :thumbsup:

luzinit
08-07-2004, 12:38 PM
great writeup, what does it do tho?

wynode
08-07-2004, 12:41 PM
*chough* 'horn' *cough

A'PEXi
08-07-2004, 12:53 PM
great writeup, what does it do tho?

VTi-RT
27-09-2004, 09:16 PM
lol, good one luzinit :p

integraz
28-09-2004, 03:26 PM
so how much hp u getting from that?
do u hear the vtec kick in harder?

ok enough stupidness for today...um why did u change the horn? is it suposed to be louder? does it have a different horn sound?

just wondering why u did it?

SPEEDCORE
29-09-2004, 12:49 PM
wOOt that thing better be playing the "La Cockaracha"!!! :)

:thumbsup: on write up!!

petrovski
02-10-2004, 12:19 AM
I did it bc i almost had a crash with my brother in the driveway ie he was reversing straight for me and he wasnt watching so i was hitting the horn and he didnt hear it . . . so i got a louder one :cool:

lol sorry no la coucaracha


Pete :)

toE
02-10-2004, 03:07 AM
OMG! Best write-up I've seen/read so far.

:thumbsup:

blackek
18-11-2004, 09:16 AM
well done dude!!!

gmonkey
06-03-2009, 12:03 AM
anychance u still got the electrical diagram that came with ur horns?? i got a 5 horn dukes of hazard horn from my old car and lost my diagram..i imagine it be almsot the same

panda[cRx]
06-03-2009, 12:24 AM
5 year old thread, good luck with that

tiksie
06-03-2009, 01:20 AM
Last Activity: 21-12-2008 12:44 AM