Help me safegaurd my wiring relays and in line fuses

[ozracer]

Whilst cleaning up some wiring on my 84 carrera and researching the nuances and gremlins that these cars attract i thought it was as good a time as ever to safegaurd some of my wiring by adding relays and in line fuses to potential fire hazards. Ive started making a list and would appreciate as much feedback as possible.

1. Headlight relay kit
2. In line fuse to headlight switch for lights 3a to post 58
3. In line fuses to footwell blowers my car doesnt have them on either side 10a
4. Ashtray grey wire from headlight switch 10a

What else can i do note car doesnt have ac..........

[porwolf]

I installed headlight relays of my own design. Actually I used 4 standard 30A automotive relays with fitting sockets, one for each high/low light system. I added four 12 gauge red wires the battery +clamp. within a few inches I added 4 in-line fuse holders with 10A fuses each. I soldered all connections and used heat-shrink tubing to insulate. Those four 12-gauge wires then connected to the four relay switch contacts. I then connected the four wires that lead from the four original Porsche light fuses to the headlights to the other side of the relay switch contacts. This way I ensured the shortest and simplest power wire connection between the battery +pole and the headlights. I connected one pole of the relay coil contacts to a body ground near the Porsche fuse box, and the other four relay coil contacts to the original Porsche headlight fuses for the headlights. I think this is a simple setup. And it seems safe because my new headlight in-line fuses are located as close as possible to the battery +terminal.

[Algernon]

Thats exactly what I did, but used relays with built-in fuses.
I don't recommend using relay sockets, as they already contain crimped quick-connects, and just add one more set of connections to cause trouble.
I combined the driver/passenger side wires for hi/lo beam, and reduced each fuse to 3A. (because each now only powers 2 relay coils.) This saves a couple of fuse positions for other purposes.
I hope this picture helps.

[ozracer]

nice work guys

[mrdieseldude]

Algernon, very nice looking work! Is there any concern of moisture getting on the fuse terminals? (in that position). Is there a cover available for the new relays?

Michael

[porwolf]

Algernon, I like the fused relays. Where did you get those?

[Algernon]

Fuses are from Pelican,
911-615-103-01-M504, about $7, Wittrin brand
or, indistinguishably different,
0-332-209-150-INT, about $14, Bosch brand.
mrdieseldude: I never thought about moisture problem - seems unlikely.

[fred cook]

You might also want to add a fuse for the instrument lights. Of course, the ultimate is to replace the original fuse panel with an ATO type panel (which I build!) w/headlight relays added. A great thing about the ATO fuses is that you can use a regular fuse, a smart fuse that "glows when it blows" or a re-setting circuit breaker. Also, the contact area for the ATO fuses is many times greater than the old VW style fuses.

[mrdieseldude]

Originally Posted by fred cook

You might also want to add a fuse for the instrument lights. Of course, the ultimate is to replace the original fuse panel with an ATO type panel (which I build!) w/headlight relays added. A great thing about the ATO fuses is that you can use a regular fuse, a smart fuse that "glows when it blows" or a re-setting circuit breaker. Also, the contact area for the ATO fuses is many times greater than the old VW style fuses.

OK Fred, at the risk of playing the fool..., what is an ATO fuse? Yes, I am going to google it now, but it might make it easier for some folks reading this thread. (there are so many fuses over the past 50 years it is tough to keep them all straight).

Michael

[porwolf]

Originally Posted by mrdieseldude

OK Fred, at the risk of playing the fool..., what is an ATO fuse? Yes, I am going to google it now, but it might make it easier for some folks reading this thread. (there are so many fuses over the past 50 years it is tough to keep them all straight).

Michael

Jumping in here:



These fuses are ATO fuses. As opposed to the original Porsche fuses. ATO fuses have better and more reliable contacts with the fuse holders.

[fred cook]

These are the type of plastic fuses that came into being about 1989 or 1990. They are made in a standard size and in a couple of mini sizes. They have a much greater contact area than the older style bullet fuses thus being more resistant to corrosion resistance at the plug. Much better design! For a picture, see what Porwolf has in his relays.

[Algernon]

These are Automotive Type fuses, either Open (underneath between the spades) or Closed (so filament is protected from moisture).