Fuse Holder Upgrade

[BadCo.]

Found my fuses yesterday, and holy crap they look less then impressive.

http://www.aulro.com/afvb/attachment.php?attachmentid=80654&stc=1&d=1405669583

As you can see number 4 on the left hand holder has melted itself in there. Turns out my heater fan is knackered.

So after seeing this I decided to upgrade all the fuses and install two of these

http://www.hella.co.nz/resources/library/07_Accessories/2010%20Catalogue%20Images/8722_Large.jpg

(see Hella catalogue here: http://www.hella.co.nz/3-444-532/product/Blade-Fuse-Box---8-Fuses

and document it a little and let you know how I did it.

I started off by removing the plate the fuse holders sit in.

After lining up the new Fuse Boxes I needed to file down the top edges circled in red just 1 to 1.5mm and drill out the mounting holes (6.5mm) circled in green.

http://www.aulro.com/afvb/attachments/coil-sprung-military-land-rovers/80926d1406005447-fuse-holder-upgrade-img_20140718_182609.jpg

After a bit of trial and error with the filing I have mounted the fuse boxes.

http://www.aulro.com/afvb/attachment.php?attachmentid=80653&stc=1&d=1405669329

Also before I could mount them I had to tin snip a bit out of the bottom lip on the back of the plate.

http://www.aulro.com/afvb/attachment.php?attachmentid=80652&stc=1&d=1405669293

Tomorrow I shall install everything back into the truck, ran out of daylight after work today.

If anyone has any suggestions of what I can do for the black out and convoy light fuses please share!

[BadCo.]

<reserved>

[Dervish]

Brilliant work Bad.

As much as I want to keep my Perentie original, barrel fuses are a bridge too far. You've just saved me a good deal of time researching which fuse holder will fit.

[BadCo.]

Brilliant work Bad.

As much as I want to keep my Perentie original, barrel fuses are a bridge too far. You've just saved me a good deal of time researching which fuse holder will fit.

No worries, just make sure you get the rear terminal one and not the side terminal.

[p38arover]

Found my fuses yesterday, and holy crap they look less then impressive.

Than.

Than!

THAN!

You sound like a bloody American using "then" instead of "than" :twisted:

How to Use Than and Then (with Cheat Sheet) - wikiHow (http://www.wikihow.com/Use-Than-and-Then)

The difference between than and then (grammar lesson) (http://www.grammar-monster.com/easily_confused/than_then.htm)

Learn the Difference Between "Than" and "Then" (http://grammartips.homestead.com/than.html)

[BadCo.]

Than.

Than!

THAN!

You sound like a bloody American using "then" instead of "than" :twisted:

How to Use Than and Then (with Cheat Sheet) - wikiHow (http://www.wikihow.com/Use-Than-and-Then)

The difference between than and then (grammar lesson) (http://www.grammar-monster.com/easily_confused/than_then.htm)

Learn the Difference Between "Than" and "Then" (http://grammartips.homestead.com/than.html)

Wow, is that ALL you picked me up on?

[neophyteguy]

Not to get too far off track here, but I've never heard an American use the English language like that.

Just saying............


Than.

Than!

THAN!

You sound like a bloody American using "then" instead of "than" :twisted:

How to Use Than and Then (with Cheat Sheet) - wikiHow (http://www.wikihow.com/Use-Than-and-Then)

The difference between than and then (grammar lesson) (http://www.grammar-monster.com/easily_confused/than_then.htm)

Learn the Difference Between "Than" and "Then" (http://grammartips.homestead.com/than.html)

[p38arover]

Wow, is that ALL you picked me up on?

That's as far as I got. :D

(oh, the link to the Hella NZ pic isn't working.)


Not to get too far off track here, but I've never heard an American use the English language like that.

Just saying............

I'm on a number of US fora and it's common.

[DBT]

Heh. I took it on board as a Kiwi accent thing. Was half expecting BadCo to respond with "Yeah, thet's what I said."

:)

Nice work on the blade fuses BadCo. Was planning to do similar, but then was pleased to discover it had already been done on my 1990 model.

[Aussie Jeepster]

Does this help?

[Aussie Jeepster]

I'll try that again!

[DBT]

Does this help?

What's a paper clip? About 50?

No reason for asking. Just curious. :angel:

[BadCo.]

It seems I can't figure out how to edit a past haha.

Anyway, I finished my mod on Sunday night. Here is how it went down...

(Apologies for the poor quality pictures, I finished around 10pm Sunday night and was working by headtorch haha)

The first lot cut and crimped, I labelled them as I went a long as I didn't feel like trying to crimp then attach them with the huge plate there, you'll see why in the next picture.
http://www.aulro.com/afvb/attachment.php?attachmentid=80916&stc=1&d=1406003818

First row attached. as you can see trying to do them one at a time crimping and attaching would have been cumbersome, unless I removed the fuse holders. But I figured simply labelling them and doing it all at once was faster and easier.
http://www.aulro.com/afvb/attachment.php?attachmentid=80922&stc=1&d=1406003818

Second row attached. Some of those feeds for the headlights are a heavier gauge and there is two of them, so it would have been easier to use the yellow (4-6mm2) spade connectors. Hindsight eh.
http://www.aulro.com/afvb/attachment.php?attachmentid=80923&stc=1&d=1406003818

The next set crimped and attached. I ended up using a lot more blue spades then I thought I would. I guess modern cars use a lot smaller cabling and more relays.
http://www.aulro.com/afvb/attachment.php?attachmentid=80924&stc=1&d=1406003818

All finished!
http://www.aulro.com/afvb/attachment.php?attachmentid=80925&stc=1&d=1406003818

The black cover was a little tricky to get on between the fuse dust covers and the gear stick boot. But it does fit!

Still looking at options for the blackout light fuses as well, I'm open to suggestions!

The great thing about these fuse holders is that you have 4 spare terminals for adding your own accessories, cigarette lighters, radios etc. For the price I was surprised by the quality of them too, the dust cover has a black rubber seal around the edge and the black plastic feels solid and not cheap.

All in all pretty happy how they turned out and hope you all took something useful from this.


-Bad

[BadCo.]

It seems I lost a picture in the original post and there must be a cut off period for editing posts.

Here is the missing picture:
http://www.aulro.com/afvb/attachment.php?attachmentid=80926&stc=1&d=1406005447

[DBT]

Very tidy work.

Even looks better than the OEM blade panel setup.

Do you have relays, flasher unit behind the plate?

[BadCo.]

Very tidy work.

Even looks better than the OEM blade panel setup.

Is the the 300ti one? I saw that one but thought it looked cheap and nasty, and wanted to used fully insulated crimps not those cheap automotive ones.

[BadCo.]

This one?
https://www.aulro.com/afvb/images/imported/2014/07/348.jpg

[BadCo.]

...

Do you have relays, flasher unit behind the plate?

Yeah there was about 4 or 5 behind the panel, all covered in aus desert dust. Not sure if I will replace them. They are probably more reliable then the cheap made in China relays you get here.

[Tombie]

What's a paper clip? About 50?

No reason for asking. Just curious. :angel:
.22 shells are 15 amp

live .22 are 15 amp with signal

[p38arover]

It seems I lost a picture in the original post and there must be a cut off period for editing posts.

I've added the missing pic to the original post and fixed the link to the Hella fusebox image.

[BadCo.]

I've added the missing pic to the original post.

Cheers mate.

-Bad

[BadCo.]

Ok decided to use another Hella fuse holder for the blackout convoy lights. This time a 4 way with side connectors to match the original and the new as much as possible. Also gives me two more spare fuses.

Hella Blade Fuse Box Side Connectors - 4 Fuses (http://www.hella.co.nz/3-444-530/product/)

http://www.hella.co.nz/resources/library/07_Accessories/2010%20Catalogue%20Images/8720-S_Large.jpg

Will hopefully get round to it this weekend.

-Bad

[BadCo.]

Alright, another update.

I have added the third fuse carrier. Was very easy, cut the old one off, drill one hole and reused an existing, bolted it down, recrimped cables.

http://www.aulro.com/afvb/attachment.php?attachmentid=81098&stc=1&d=1406336660

Unfortunately because this one is surface mounted it protruded ever so slightly more then the other two and the black plastic cover that goes over the whole lot doesn't sit perfectly on the left hand side.

But it works fine without the clear cover, so a small compromise.

I have also filled the spare holders with spare fuses just in case and put extra crimps over the spare exposed terminals to protect them a little.

[Outlaw]

Just found this. Nice work on the fuse upgrade. Bookmarked for later use :D

[Lotz-A-Landies]

Brilliant work Bad.

As much as I want to keep my Perentie original, barrel fuses are a bridge too far. You've just saved me a good deal of time researching which fuse holder will fit.The Defenders from about 1991, possibly before, have a blade fuse panel in exactly the same location. Perhaps a retrofit is another option.

I'm having problems with the panel and the LH low beam fuse (no.2 RHS) and am currently looking at my options.

[BadCo.]

You can get the later model parts off ebay and from the UK, I preferred doing it my way though :P better quality I reckon.

[Dervish]

The Defenders from about 1991, possibly before, have a blade fuse panel in exactly the same location. Perhaps a retrofit is another option.

I'm having problems with the panel and the LH low beam fuse (no.2 RHS) and am currently looking at my options.

I had thought of that, but it would mean replacing not just the fuse boxes but the panel they mount in as well. The later fuse box is a very different shape to the early one and it would make a mess trying to fit the later fuse box into the early panel. Replacing the panel as well is certainly not a show stopper, but I figured that would get expensive.

I will check what the local LR wrecker wants for the bits, but I'm not going to hold my breath as to whether it will be "worth it" (the worth it bar is quite low at the moment as the old fuses haven't caused any fuss for the past few months).

[BadCo.]

I had thought of that, but it would mean replacing not just the fuse boxes but the panel they mount in as well. The later fuse box is a very different shape to the early one and it would make a mess trying to fit the later fuse box into the early panel. Replacing the panel as well is certainly not a show stopper, but I figured that would get expensive.

I will check what the local LR wrecker wants for the bits, but I'm not going to hold my breath as to whether it will be "worth it" (the worth it bar is quite low at the moment as the old fuses haven't caused any fuss for the past few months).

If you are good with your routine maintenance, keeping the contacts clean etc, then they should last forever. Mine were already well corroded and one fuse melted itself to the fuse holder and I'm a sparky so it was an obvious choice to do the upgrade.

[brad56]

Great information Badco will book mark it for later use.

[BadCo.]

FYI

From memory it was Hella 8722

Blade Fuse Box - 8 Fuses (https://www.hella.co.nz/en/products/accessories/fuse-boxes-holders/blade-fuse-box-8-fuses.html)