Okay!!

I put the switch components together today. I used a 2" X 6" plastic project box from Radio shack and mounted the toggle switch and fuse holder inside. I soldered and heat shrunk all connections.

The box itself is not waterproof but has a small lip on the top to which I attached an elastic band. This seal is probably not waterproof by itself although I only intended it as one part of a sealing system.

I put the box top on and did a temporary seal around the joint and 4 screws.

Once all this was done, I immersed the whole thing in a bucket of water for 1/2 hour. After 30 min. I took it out, dried the outside off, removed the temporary seal and removed the screws. And.....

Totally dry!!!

The temporary seal will be replaced with a urethane adhesive/sealer once the whole system is complete.

I used a screw type fuse holder and sealed it with an air conditioning O-ring. The fuse can be replaced without opening the box.

I was thinking of putting a small light in the system to tell me when it was on but changed my mind. I intend on mounting the switch inside the cockpit between the seat and the hull and a light would be useless here. I decided to use one of 2 other methods; I will either mount the pump in contact with the seat so I can feel it when it is on or else I will install a small piezo buzzer inside the switch box so I can hear it.

Now, I have to buy a battery and mount the system in the boat. Maybe the boss will turn his back again tomorrow!!

Total time building and wiring pump- about 30 minutes.

Cost- about $10.00 Canadian.

Ian