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Quote:
Originally Posted by bugstrider View Post
A word in the nylon threaded self locking screws. It is very important to pay heed to the "instructions" of not over torquing them as you tighten the wires down.
Hmm, I'm not convinced that nylon is a good choice for these screws. Screw terminals rely on the screw deforming and squashing the ferule in order to make a good contact. Some of the 42A wires are pretty heavy and I doubt you could apply enough torque to properly support that much current.

As you know when you undid the original fuses, Porsche did the screws up pretty tight!

The terminals on our panels are metal:





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Old 10-26-2017, 01:05 AM
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As I previously posted, ReFuze was designed with nylon screws to eliminate exposed metal carrying a lot of current capacity and to avoid putting excess stress on the wires/ferules. The self locking thread feature keeps the connection secure.

If one perceives the need for a metal screw on larger wires, the nylon screw can be replaced with an 8-32 x 5/8 brass screw, which will also engage the self locking thread feature.

With well on toward 200 units shipped, the use of nylon screws has proven to be successful and the correct design decision for ReFuze.
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CDD Autogear manufactures ReFuze ATO fuse panels to retrofit all 356, 912 and 911 Porsches up to and including 1989

Last edited by CDD Autogear; 10-26-2017 at 01:15 PM..
Old 10-26-2017, 12:46 PM
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Quote:
Originally Posted by CDD Autogear View Post
< snip >

If one perceives the need for a metal screw on larger wires the nylon screw is easily replaced with an 8-32 x 5/8 brass screw which will also engage the self locking thread feature.
< snip >
For those so inclined: https://www.mcmaster.com/#93465a196/=19zg8o7
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Old 10-26-2017, 01:11 PM
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This seems to be an outstanding upgrade to the wiring on our 'precious' cars; an upgrade that I'm seriously considering.

But, here's the rub: things like this while almost certainly make the car better, also take one more step away from 'original.' I suppose one could keep the old, original stuff in a Zip-Lock bag to pass on the next owner if she/he just HAD to be "all original."

Frankly, I think this worship of originality is a bit much. There are improvements that can be made that probably should be made, originality be damned.
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Old 10-26-2017, 01:16 PM
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Dang you folks!

Now I have a new crimper on order. Another toy, um er tool.
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Old 10-26-2017, 01:30 PM
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ReFuze is an exact fit with the same fuse/wire spacing as OEM blocks making it a "drag and drop" form factor. No relocating wires required.

This makes returning to original OEM blocks as easy as installing ReFuze.
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CDD Autogear manufactures ReFuze ATO fuse panels to retrofit all 356, 912 and 911 Porsches up to and including 1989
Old 10-26-2017, 01:32 PM
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Quote:
Originally Posted by CDD Autogear View Post
< snip >

This makes returning to original OEM blocks as easy as installing ReFuze.
Yay !
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1987 911 Coupe, Black M491 3.4 // Turbo-Look Registry # 1249
1977 911 Coupe, Metallic Sienna (I think!)/Lobster SOLD
1982 924 White, SOLD long ago
1966 912 Red, SOLD, totaled a week later by its new owner
Old 10-26-2017, 01:34 PM
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My &quot;ReFuze&quot; panel upgrade adventure

Rated fuse configuration:

Howdy......again,

It's been a couple of days since I finished my upgrade to my OEM fuse bar to the ReFuze It ATO upgraded fuse bar. I still have not hooked the battery up to test the system. In one of my parting shots with my OEM fuses sitting on top of the new fuse bar, really got me thinking about the rated fuses in the assigned positions. Like so many of us who's cars had a PO or multiple PO's, many alterations may or may not have been made. Even repair shops make slight changes to fuses depending on what's on hand in their inventory.

Where I am going with all of this is simple. After taking the time to do the upgrade, I now want to make absolutely sure that I have all the correct rated fuses in their proper positions. To do this, one would think it's a simple affair. Unfortunately, there are so many reference pics of fuses for all models, it's difficult to pinpoint the correct one for a particular year. Consider the changes to the electrical demand with just the SC during its reign. I have discovered that the 78-79 SC was a two year only version with certain nuances that are absent on the 1980 year and beyond.

Luckily, I was able to locate our 1978 911SC owners manual and referenced the proper fuse configuration page. Upon review, I immediately discovered discrepancies between what I found on the OEM board and what is referenced in the book. I know ignorance is no excuse, but not knowing caused me to inadvertently mirror the new fuse sequence with the old which was incorrect and potentially put the car at risk of an electrical short and or fire.

In searching for the correct fuse alignment, I ran across an older post where a member explained the risks of having a higher rated fuse in the incorrect slot, potentially causing a risk of overload. This really drove home the point, at least it did to me.

So for the sake of references, I am posting the proper fuse sequence for our car, which is a 1978 911SC US car.
Hope this helps my fellow 78SC owners. Now I can be sure I have all the properly rated fuses in their proper positions.


In my OEM fuse bar, I do not have a single 5 amp fuse in the run. They were replaced with all 8 amp fuses at some point in the past. There are probably a few who will say this is no biggie. I will make sure my upgrade will mirror the proper sequence listed in the Owners Guide.

Cheers Bugs
Aka "Trevor"



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Last edited by bugstrider; 10-27-2017 at 06:08 AM..
Old 10-26-2017, 09:33 PM
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good post
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Old 10-26-2017, 10:14 PM
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Great write-up! Thanks for reminding us that our wiring may be different than OEM.
Are you still comfortable with your choice of the plastic terminals over brass? Has anyone found another provider (besides the two mentioned) or a diy solution to buy individual parts and fuse panels? I have been forced to consider this upgrade as I tear my fuse panel apart cleaning and hunting for a problem in one of my turn signal circuits.
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Old 10-27-2017, 04:53 AM
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Quote:
Originally Posted by Hot Euro View Post
Great write-up! Thanks for reminding us that our wiring may be different than OEM.
Are you still comfortable with your choice of the plastic terminals over brass? Has anyone found another provider (besides the two mentioned) or a diy solution to buy individual parts and fuse panels? I have been forced to consider this upgrade as I tear my fuse panel apart cleaning and hunting for a problem in one of my turn signal circuits.
Advanced title search for ATO yields a buch.
Pelican Parts Technical BBS - Search Results
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Old 10-27-2017, 08:03 AM
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Hot Euro

ReFuze terminals are not plastic. The screws securing the wires are nylon. The connection between a wire and its fuse is made using a single brass stamping. Ganged terminals are single brass stampings as well. There are no staked or soldered connections, which can corrode or loosen, used anywhere in the design of ReFuze.
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CDD Autogear manufactures ReFuze ATO fuse panels to retrofit all 356, 912 and 911 Porsches up to and including 1989

Last edited by CDD Autogear; 10-27-2017 at 08:43 AM..
Old 10-27-2017, 08:20 AM
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Quote:
Originally Posted by CDD Autogear View Post
Hot Euro

ReFuze terminals are not plastic. The screws securing the wires are nylon. The connection between a wire and its fuse is made using a single brass stamping. Ganged terminals are single brass stampings as well. There are no staked or soldered connections, which can corrode or loosen, used anywhere in the design of ReFuze.
Are the [female] parts - the parts into which the screws thread - of the ReFuze panels plastic or metal?
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1977 911 Coupe, Metallic Sienna (I think!)/Lobster SOLD
1982 924 White, SOLD long ago
1966 912 Red, SOLD, totaled a week later by its new owner
Old 10-27-2017, 01:30 PM
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Quote:
Originally Posted by RFP View Post
Are the [female] parts - the parts into which the screws thread - of the ReFuze panels plastic or metal?
The screws screw into threaded brass inserts embedded into the plastic housing.
Old 10-27-2017, 02:07 PM
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Quote:
Originally Posted by CDD Autogear View Post
The screws screw into threaded brass inserts embedded into the plastic housing.
Nice! Thanks...
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1987 911 Coupe, Black M491 3.4 // Turbo-Look Registry # 1249
1977 911 Coupe, Metallic Sienna (I think!)/Lobster SOLD
1982 924 White, SOLD long ago
1966 912 Red, SOLD, totaled a week later by its new owner
Old 10-27-2017, 02:14 PM
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For a visual reference:




Cheers



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Old 10-27-2017, 03:09 PM
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From when I did my replacement with the ReFuze boxes, my impression was that the U-shaped brass inserts offered more contact surface than the stock setup. I didn't tin my wires or use ferules because it didn't seem necessary & took away from the flexibility in the tight space I had. Plus the originals weren't tinned or fitted with ferules. Maybe I will go back some day and do that, don't know. I tightened the nylon screws down fairly snugly, and not more. That seemed to hold the wire ends well, and like I said I had to lengthen all of them maybe up to two inches to help ease the installation. I'd imagine there will be/have been people who ruin the screws by tightening them too much. Like Alan says, you can either replace them with brass ones or work out some arrangement with him for replacements.
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Old 10-27-2017, 03:46 PM
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After re-referencing my proper fuse alignment, this is the end result with everything in its proper place. I'm surprised there wasn't an issue....



It is interesting to see the differences when compared to old vs new(proper) as listed in the owner's manual.

Cheers and happy Saturday everyone.


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"What the hell is an Aluminum Falcon??"
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Working Projects: 1968 912
Old 10-28-2017, 09:49 AM
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OCD-nerd alert!!!
(You have been warned)

As you probably recall reading that we bought a Brother P-Touch label maker.........well.

I buttoned everything up today. Re-wrapped the headlight relay wires with smaller plastic shroud then wrapped in black electrical tape. Affixed the extra 3 fuse triple ganged box for added future accessories. Numbered each fuse according to the fuse bar cover(inside) and labeled each relay for easy reference. Also secured the ground wires for the seat heaters and "timmy2" custom relay(work of art BTW) and then cleaned up the zip ties and used some self adhesive zip tie bases.

You were warned..............












Nite-O





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"What the hell is an Aluminum Falcon??"
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1978 911SC Targa
Working Projects: 1968 912
Old 10-29-2017, 08:36 PM
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All that work and money and its now out of sight.
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Old 10-30-2017, 02:19 AM
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