[Done] Rain-Sensing Wipers Installed

[swooshdave]

Five-month update.
Electrically, it's been working fine.
Visually, the vinyl kept trying to pull away from the glass, resulting in a visible pattern on the outside in the shape of the bracket. Of course, I somehow failed to get any pictures of this.

My thought was to switch to a two-layer setup like I'm doing in the Flex -- apply glass primer to the windshield, then a layer of vinyl over it. My thought was the vinyl might stick better to primer, and any air pockets would be hidden. I had my camera all set up so I could record a full howto on the installation.

Well, applying the primer didn't go as planned and on the third attempt, spilled it all over my hands. The gel on the rain sensor also got pretty messed up, so I have more shipping from aliexpress ($6 for eight vs $35 for one on Amazon)

Decided to modify the bracket design. The first version was meant to replicate the OEM bracket 1:1 so it'd be compatible with OEM covers, with an optional 'shorter' cover that would have to be printed.
New design increases the surface area but isn't directly compatible with OEM covers. Maybe it'd work if you broke the tabs off.

I also got nervous about having too much surface area because I broke the Flex's windshield using epoxy over too large of an area. Instead, I used high-temp VHB tape to apply the bracket this time. Dialed in the vinyl template design a little closer, too.

So I guess we'll see again. The increased surface area should hopefully help prevent pulling away. If I can find one of my spare rain sensor covers, I'll see if it can attach directly to this mount. I'm honestly hoping so, because I haven't found a good way to print the cover that didn't result in an obvious '3d printed' appearance.

Also debating having the first layer of vinyl being properly shaped to match the existing frit, then put three or four additional 'rough" layers just where the bracket mounts for extra strength. I can already kinda see where the tape is, though that could just be from the vinyl still needing to even out

What is causing the pressure/tension on the vinyl?

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[XirallicBolts]

What is causing the pressure/tension on the vinyl?

The rain sensor has to press against the glass relatively tight. This essentially 'pulls' the bracket away from the glass, taking the vinyl with it. Honestly I'm a bit frustrated with how my method split in two directions, neither of which is quite as straightforward as I'd like.

Ideally the best way to do this would be

• Apply a layer of glass primer to the entire work area
• Apply vinyl just to the edges
• Use a template to remove primer at the sensor and edges
• JBweld metal mounting bracket directly to primer

This would give the best overall result, but I didn't want to permanently adhere a bracket to the windshield. The purpose of the vinyl was to make all of this 100% reversible.
So my current 'alternate' method is a bigger non-factory-style mounting bracket that can be attached over a wider area. I really should've primered first to make the vinyl stick better and be more even, but my primer had all gone bad.

---

You can see how I did the 'permanent' method in this video -- it's been strong enough to hold a heavy rearview mirror in place. Also dear god my voice sounds weird :X I really wish YouTube would let me replace the audio without having to reupload the whole thing and losing the handful of views I've already accrued.

 

[ShinHee Han]

Edit: Full installation post

My Flex needs a windshield replacement. Considering they're going to swap over the rain sensor to the new glass anyway, figured this was a good opportunity to test it on the Bronco. A rough test with dangling wires and the sensor crudely stuck onto the windshield was enough to determine that the Bronco does support rain sensing.

Wiring is simple: Power, Ground, and LIN. The LIN needs to tap into the yellow/grey wire running between the SCCM and wiper motor. Easiest access is by removing the steering column shroud (3x 7mm screws). On the sensor, Pin 1 is accessory power, Pin 2 is LIN, Pin 3 is ground.

Parts (pick one from each group):

• Rain Sensor - $40
  • LU5Z-17D547-B
  • LU5Z-17D547-A, only difference is retaining clip orientation.
• Rain Sensor Cover - $0 to $20
  • BL3Z-17D550-A
  • 3D Print your own (PETG)
• Rain Sensor Bracket
  • AliExpress reproduction
  • 3D Print your own (ASA preferred, PETG might be ok)
• Connectors
  • WPT-1096 Pigtail
  • 3-position DuPont female headers
  • Crimp your own DuPont headers
• Adhesive - $12
  • 3M VHB GPH-series, designed to withstand higher temperatures than normal VHB
• Vinyl - $2
  • Oracal 651 Vinyl, matte black

You also have the option of visiting the junkyard to get the sensor, bracket, cover, and pigtail. Be careful not to get the sensor gel dirty, replacement gel is half the cost of a brand new sensor.
I tried using Cricut software to cut the vinyl but it's not an easy program for me to figure out. I ended up using my 3d printer as a vinyl cutter instead.

AsBuilt changes were all done through easy mode.

• SCCM: Rain Sensing Wiper [ENABLE]
• SCCM: Rain Sensor [ENABLE]
• APIM: Rain Sensing Wiper [ENABLE]

With the sensor stuck to the windshield and AsBuilt changes made, I turned the wiper control to Intermittent. It performed one wipe, then waited ~15 seconds and parked the blades. After that it was ready and responded as expected to water hitting the sensor! A heavier mist would result in faster wiping. If no water is detected after ~30 seconds, it parks the blades.

When the 'Rain Sensing' option is turned off, the intermittent stalk positions work like factory.
When the "Rain Sensing' option is turned on, the intermittent stalk positions adjust sensitivity, with Constant Slow and Constant High still overriding like factory.

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Now that we know the Bronco can support it, I have to make it look good.

Things get a little trickier at this point.

First problem: The masking around the rain sensor in factory applications. This one should be an easy fix, a little Oracal 651 permanent vinyl, trimmed to match the correct shape and applied to the inside of the windshield. This is exactly what I did on the Flex to add lane-assist. From the outside it looks similar enough to the normal black masking. A Cricut is probably needed to get a perfect circle.

Second problem: The mounting bracket. You can't buy these from the dealer or official parts sites, they're considered integral to the windshield. Your options are junkyard pull, 3D-print, CNC, or buy a replica bracket off Aliexpress.

So that's where I'm at right now. Proof of concept worked, now time to make it look relatively factory.
I'll order a sensor and design the bracket/vinyl template, updating this thread as I do so with more details.

LIN wire in steering column. Luckily it's the only mostly-yellow wire that isn't in a twisted pair, making identification easy.

A more likely location

Oracal 651 vinyl stuck to the inside of the Flex's windshield to mimic the masking on cars that normally have lane-assist.

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