New Fuse Box Project w/Flat Style Fuses

[Ove]

Here are some pictures of my latest fuse box project.
I upgraded to flat style fuses a long time ago, with a new fuse panel in the original location. But I decided to move the fuses inside an aluminum bow for a more tidy look.
At the same time I made a relay panel where the stock fuse panel used to be to hold a total of 8 relays. 4 of them are for the lights to ensure maximum light output and to prevent the common(?) meltdown of the light switch at the steering column.

Not quite finished – I need to connect a few more wires and paint the relay panel black.

[Ove]

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[Ove]

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[azasadny]

Very nice work!!!

[cali74]

awesome!....definate copycat work will happen with this project (as with your previously awesome fuse upgrade project) :-)

[Johnb911]

Great work!!!!!

Where did you get the relay enclosure you are using?

[Ove]

Thanks guys

This is where I got the aluminum box:
http://www.jaycar.com.au/productResults.asp?FORM=CAT

Very fast shipping (from Australia).
Select "enclosures" and "aluminum" from the left menu.

But I´m sure there are many shops in the US selling similar enclosures.

[imcarthur]

Great job. The holes on your fabbed bracket threw me at first until I realized your car's on a diet.

Ian

[Ove]

Here´s an update w/more pictures:





I used a small LED as an indicator for when the main power is turned on with the battery disconnect switch.

[HarryD]

That is very nice but do the next owner a favor and very carefully label all of the fuses and wires. Include a detailed wiring diagram as well that shows how you moved from factory setup to yours including the wire color changes.

One problem you may have is getting someone else to work on the electricals with the modified box. Because they can not be absolutely certain that the wiring conforms to the factory layout, they may charge extra to trace the circuits and then not warranty the work anyway.

[Ove]

Harry,

Problems having someone else working on the electrics is not an issue as I do all the work myself

I made several wiring diagrams during this project. I'm keeping the final diagram in the car with the registration documents. The main difference is that I added four relays for the lights.

I follow the factory fuse locations if you start counting fuses from the rear of the stock fuse panel. My new fuse no.1 is located right rear (rear of the car). Fuse no.11 is on the second row, left rear.
I'm thinking of putting labels on the fuse box lid, next to each fuse to identify the circuts.

[Kroggers]

Ove, that is some nice work. I will have to use some of those ideas when I do my fuse and relay upgrade
Do you have more info on that washer bottle upgrade??

[Ove]

Pål,

Thanks

The washer bottle is for the rear window of an 1983-87 Mazda 626. The stock 911 washer bottle was too heavy.
I'll see if I can find some pictures of the bracket I made to hold it.

[81 911 SC]

Excellent work.

[scottb]

Are you leaving the fuse box mounted to the floor of the trunk? If so, and if you put something in the trunk, don't you risk it sliding over and damaging the exposed fuses?

[Ove]

Pål,

Here are some pictures of the lightweight washer bottle:

[randywebb]

Ok, that's 230 g. all up with the pump mounted (?)

How much did the stock washer bottle weigh?

[Danimal16]

Ove,

Where did you obtain the stipped color coded automotive wire for your current project? Also, are you using crimped connectors? Also, what are the dimension of the box?

Your first project was awesome, but this one really has the makings of a significant improvement on the seemingly perfection of your first selection.

Fantastic work.

[HarryD]

Originally posted by Ove
Harry,

Problems having someone else working on the electrics is not an issue as I do all the work myself

I made several wiring diagrams during this project. I'm keeping the final diagram in the car with the registration documents. The main difference is that I added four relays for the lights.

I follow the factory fuse locations if you start counting fuses from the rear of the stock fuse panel. My new fuse no.1 is located right rear (rear of the car). Fuse no.11 is on the second row, left rear.
I'm thinking of putting labels on the fuse box lid, next to each fuse to identify the circuts.

Like I said, it is a nice looking job. Just looking down the road to what the future may bring.

By all means, get the labeling and drawings done now while it is fresh in your mind. Later, if you do not, you will find the details hard to recall. You will thank yourself many times over when you are troubleshooting a short at the other end of the car.

[Ove]

Thanks Dan

The yellow/green wire was purchased at "Biltema", a scandinavian auto parts shop. I got the fuse holders, relays and relay holders at the same place. Yellow/green wires are used for ground in houses/household electrics (220V). This is a "special" wire because it's very flexible and has a lot of individual copper cords, making it suitable for automotive use. Normal household wires are not recommended for use in a car.

The 10x fuse holders were less than $ 10 each and fit the enclosure perfectly. I used a threaded "spacer" to get them at the right height inside the box.

I used crimped connectors at the fuse box connections, but I may solder them later. All wire-to-wire connections are soldered and covered with heat shrink tubing. This is time consuming, but must be done to avoid problems in the future.

The enclosure was purchased at Jaycar (see the link above)
Order details:
Sealed Diecast Aluminum Enclosure - 222 x 146 x 55mm
STOCK-CODE:HB5050
$36.95 (Australian $)
Shipping was $10 to Europe

Harry,

I couldn't agree more. Without a diagram a project like this could create more problems than it solves..