DIY fuse box

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speedrye

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Stokesdale, NC
I needed to clean my wiring and relays up, so I decided a new fuse box was in order. Enter the Bussmann box:
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It'll hold 10 relays and 40 fuses. I'm using it a little differently and it'll only have 10 relays and 20 fuses, but it should power all my lights and misc. interior electronics.
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Lots of friggin' wiring out the back. Simple connectors for everything as well:
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Had a bracket cut and bent while I was doing the front bumper:
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New mounting holes drilled for solenoid and mounting to fender. Primed and painted as well:
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Solenoid mounted to bracket. Provides 200A of power to block when ignition is on:
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Final mounting. Wires will be cleaned up some when new bumper is done and lights are reattached:
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As it is now, it's powering 5 pairs of lights, CB, video system, heated seats with much more expandability.
 
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speedrye

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Jan 24, 2013
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Stokesdale, NC
Terminals come from the Delphi Packard 280 Series Metri-Pack line. They come in male and female and each is dependent on the wiring gauge that you're using. The cavity plugs are the same way and come in different colors per wire gauge. The colors are hard to find corresponding wire gauges for, but I believe this is correct:

12 gauge = Blue
14-16 gauge = Gray
16-18 gauge = Green
18-20 gauge = Tan
20-22 gauge = Purple
22-24 gauge = Red

Install is simple. You slide a cavity plug on the wire you're connecting. Crimp the male or female terminal to the wire. I soldered mine after this as an added precaution. Slide the terminal in to the connector or housing until it clicks in place. Slide the cavity plug along the wire until it's plugging the cavity at the back of the housing or connector. Done. Repeat as needed.

Female terminals plug in to the rear of the main fuse box housing. Male and female terminals are used on male and female connectors. Order as needed.

Many of the connectors, plugs and terminals need to be bought in multiples since that's how supply houses sell them. You're likely to end up with some extras. Being that these items are small, the shipping isn't too bad, but most supply houses do charge a handling fee to pick out 10 of item X, 20 of item Y, 50 of item Z, etc.

So far, I've purchased all of my items from Waytek, but there are other places. Here are a few links for sales and references:
http://www.whiteproducts.com/sealed280.shtml
http://www.waytekwire.com/products/1...80-Series&pg=1
http://delphi.com/connectors/assets/...ure/met280.pdf
 
GLTHFJ60

GLTHFJ60

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Is this just an aux fuse box or are you replacing the factory box entirely? Pretty overkill for an aux box, no?

Either way, beautiful work :D
 
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speedrye

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Stokesdale, NC
This is just an aux. box, but for the money it was cheaper and cleaner than any aftermarket solution out there. The biggest issue is that I needed more than the 5-6 relays that most other boxes come with, so this uses less space in the end with more options for expandability. I love me some overkill though!
 
lt1fire

lt1fire

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Location
Seattle, WA
Looks great, I may do this to just rewire my old suburban as I need to chase some bad wires down and hate where they put the fuse panel in those trucks... .have to be a contortionist to get to it. :cheers:
 

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