Cheap and easy ATO fuse block installation

[Algernon]

I found a cheap and easy replacement for the old corroding Porsche fuses. I just replaced my 21 way fuse block with an ATO block. They are available in 6, 9, 12 and 15 way, but only had 6 and 15 in stock recently.
They fit almost exactly in place of the old blocks - even the original metric screws were used after I slightly enlarged the holes in the new blocks.The new blocks are the same width and slightly shorter than original ones. I think 15 and 9 way would probably fit, if extra fuses were needed. I have 2 spare places as I only needed 2 fuses to drive the 4 headlight relays.
These panels accept wires under a clamp with Torx T15 screw head.
The original Porsche wire ends in the fuse box have small brass tubes crimped on them and these slip easily under the new clamps. Except for a few really thick red wires. For each of these, I separated the wire strands into 2 groups, and fed them to either side of the screw clamps.
With the ATO fuses in place, the new blocks are about 1/10 inch too tall for the fuse cover to fit!! But the metal tabs at the bottom edge of the box can be bent upwards by that much, so the cover can fit perfectly after all!!
I recorded and carefully marked each wire before disconnecting it, took about an hour.
Then replaced the block and reconnected the wires. Took about another hour, mainly because of the thick wires.

The blocks are part number FP-ATO-S06, FP-ATO-S15, priced at $5.58 and $21.87
They are made by GEP Power Products, but sold by them only in huge quantities!
They are distributed by Chief Enterprises, in Elmhurst, IL. in single quantities, and accept phone orders on 1-800-831-7294 or 630-530-1224.
I found them very obliging. (I have no connection to this firm).
So for 2 hours work and $30 this is a great improvement. Enjoy!

[GaryR]

Thank you Algernon, well done!

[IXjamesXI]

Wow.. that looks really tidy.. I am going to consider this for my car..!

[GaryR]

Fresh, clean connections using modern easy to find and replace fuses. Chief has a Web Store - http://store.chiefenterprises.com/ but neither of those part numbers work.. did find a 12 fuse panel though - http://store.chiefenterprises.com/Products/Multiple-Fuse-Relay-Holders/FP-ATO-S12

Guess a phone call is required for the odd sizes but 2 12's should fill it up quite well, $36.xx shipped.

[timmy2]

2 -12's is what I ordered a few weeks ago from them.
Nice product. Will install this winter when I do everything else I'm planning to do to my car.

[Kemo]

nice! and it looks like an easy reversal if need be.

[Algernon]

Originally Posted by Kemo

nice! and it looks like an easy reversal if need be.

Yes, that's another bonus!

I imagine 2 x 12way will also work fine.

[kidrock]

That ought to keep those nasty feral cats out.

[targa44]

It looks like the "bridging" you'd find on the back of the original panel was accommodated on the new panel by spliting the large red feeds and putting in red wire loops to the appropriate fuses to achieve the same effect?

Nice job.

thanks,

[wildcat077]

I did the same thing over last Winter,although it was Fred Cook's system,you definitely have to follow the wiring diagram and bridge the correct wires !
It seems intimidating at first but when it's all done you realize how simple it really is ...

Cheers
Phil

[Algernon]

Originally Posted by targa44

It looks like the "bridging" you'd find on the back of the original panel was accommodated on the new panel by spliting the large red feeds and putting in red wire loops to the appropriate fuses to achieve the same effect?

Nice job.

thanks,

Yes, exactly! I didn't realize there were extra links on the back of the old fuse holders until I turned them over! Good thing I looked!

[targa44]

... just thought of something.... (I was mistaken about the type of connection and now realize it's the 'blade' type fuse connector.

Although yours fit together nicely, I'm wondering if one were to install the blade crimp on connector to each wire - if the splitting of the main red feed would be necessary?

Question: do you think the connection could easily handle a stack of three blade connectors? A few of my old '73 wires have 3 into 1.

thanks,

[Algernon]

Originally Posted by targa44

... just thought of something.... (I was mistaken about the type of connection and now realize it's the 'blade' type fuse connector.

Although yours fit together nicely, I'm wondering if one were to install the blade crimp on connector to each wire - if the splitting of the main red feed would be necessary?

Question: do you think the connection could easily handle a stack of three blade connectors? A few of my old '73 wires have 3 into 1.

thanks,

The reason I really like this type of fuse block is it avoids having to put on any crimp-on connectors! I was not confident that I could get a good enough crimp to avoid future problems.
And to have to go over each crimp with a soldering iron seemed like a real pain, kneeling in the cramped conditions of the trunk.

Further, as the original Porsche terminations have a crimped tube(?) on each wire end, this would need to be cut off and then a new bare end stripped off before even starting to re-crimp. All that work!! Might as well go with Fred's dis-connect method.

With the screw clamp really wide open, yes, I think 3 of the open-mouth type 'spade' connectors would go in fine.
However, the barrel parts of the connectors, containing the wires themselves, might be hard to stack. You could try stuffing more than one wire into a single barrel. You have still got to re-terminate the wire which creates another potential trouble spot if not crimped with enough force!

Actually I had several places where 3 or even 4 wires went to one spot. Because the screw to each fuse place is centrally positioned in the clamp, one or even 2 wires can go either side! So I had no trouble fitting then all in, even with the Porsche terminations.

A couple of the Porsche terminations had got mashed over the years by the original screw points, so I had to massage them a bit to get them to fit.
I tried to get the same amount of wire on each side of the screw, so that it clamped down smoothly. (for the big red wires - I really think a good crimp or solder connection would take a lot of effort!)

But actually the Porsche terminations made things a bit easier as they looked somewhat cleaner than the 30+ years old copper wire itself. I hated the thought of getting a clean solder join without damaging the insulation. Especially as some of the wires were already quite short!

I hope this helps, it was really not so bad. Worse part was making sure every wire was labeled, and I didn't forget any of the 'hidden' connections originally on the back of the blocks!

[kuehl]

That is sweet Al.

I'm going to sticky note this one for a winter project.

PP should package this one.

Griff

[175K911]

Wow, Elmhurst is just 15 minutes from me, and I drove through there yesterday. Need to hop over there next week and pick up a couple pieces for myself. I have one of Fred Cook's panels that I haven't installed yet, but this looks far easier.

Nice find Algernon!!

[Canada Kev]

If you're putting the bare stranded wire into the panel, be sure to tighten up the screw that holds them down after a few miles. The stranded wire will loosen from under the clamp with a bit of vibration. It's just the wire compressing and a quick check of the tightness of the screw should eliminate the possibility of any flaky connections later on.

Great idea and good luck!

[Algernon]

Next time I do this, I will substitute one of these for the left hand group of fuses, to eliminate the 'big red' wire problem. These blocks already have the fuses ganged or 'bussed' together!
http://www.ceautoelectricsupply.com/fuseholders.html
I wish now I'd seen them before. In fact I might retro-fit one if numbers fit.

[donporfi]

To avoid the red wire loops you can make a copper bridge like this one:
(this one is a dummy just to show you how I think it should look like, I would use a copper strip of 18 or 20 gage.)

[al lkosmal]

What is the current rating of those fuse blocks?

[timmy2]

30 amps per fuse circuit.
GEP Power Products - ATO Blade Type Fuse Panels