Replacement Fuse Blocks and Possibly TERMINALS

[motoman]

Anytime Laxdad............That was the simplest remedy to mounting for me. More time consuming, could've cut thin aluminum plate to cover opening using the original screws and holes, mounted using plastic spacers for space to put nuts on backside of new mounting holes for new style fuse block. Figured that was a bit overkill, and this mounting style looks good. The key to a nice look anyway is using 90 degree crimp on connectors.........Sounds like you got it all under control.

[DeanR]

Plastic is drilled and dremelled. All mounted up straight and tight. Now just have to cut perfectly good wires! Thanks for the advise.

[motoman]

Don't drill re-drill the plate!...Drill the new fuse block as I stated. re-read and you'll understand. If not, let me know here or IM....I'll get ya lined out.

[DeanR]

Hi Motoman, thanks for the quick detailed response! I'm sitting here with the mounting plate in my hand ready to drill. The hole that is required is Right Next to the edge of the metal plate and there is the circular raised area with the integral nut on the backside that makes matters a little worse for drilling. Should be obvious and easy but can't quite visualize where to drill! Duh.
Wish I had a digital camera for a pic worth a thousand words.

[motoman]

fuse block

One more thig Laxdad..........The hole thats redrilled WILL come close to edge of new panel. You'll find the quality of base is fairly dense and hard and having hole close to edge won't be a problem. This will give you the distance between holes that's needed, and leave enough of slotted side to hold well with the small flat washers. The square opening of base plate won't be totally covered, but wiring harness covers most of opening , and isn't noticed anyway. All done, it'll look like it was original to any who aren't observant XS'ers...........Happy mounting!

[motoman]

fuse block

Yeppers Laxdad...........don't have any pics, but you'll see that the two holes on block are offset. Make the left side hole an open slot witha dremal cut-off wheell or hack saw blade. Go above the existing hole on right side of fuse block,to a point straight across left side hole and drill new hole. Remove your existing fuse panel, leaving wires attached, pulled to one side. Mount new fuse block using your same screws and add a flat washer to each. Clip each wire close to old crimp of fuse holder and use 90 degree blade ends so wires come out toward you, not vertical. Plug on each one as you go. Run the wires for the lower connections to the front, down around the front side of new fuse panel. This will keep you from having to find some slack in the harness. after having all wires hooked back up, use three small plastic wire ties to attach lower wires in a small bundle. Also put a small dab of dielectric silocone compound(from your local auto-parts store) on each connection and fuse before plugging them in. The job completed like explained will look very professional and that part of electrical system will be trouble free.

[Jdwags]

fuse boxes

Still have any? Its starting to get nice and life seems to be calming down again a bit..

Course when the 9 yr old is sitting on the bike asking when im gonna put it back on the road... that does help with the motivation

BTW, hi everyone, im back in a limited capacity- life has been pretty rough the past 2 years.

[DeanR]

The new block just misses the two stock mounting screws on the metal plate by like 3/8 inch. Anybody figure an easy way to get it mounted up?

[DeanR]

thanks guys.

[GNEPIG]

.. i measured the wires this morning, looks like the small wires might be 20 gauge and the large might be 14 gauge

[TopCatGr58]

You say Potato!

Dean,

According to my electronics parts catalog, it uses ATC and ATO interchangeably, and the holders says things like for
ATC/ATO type fuses!! The smaller ones are called Mini, and the glass ones are AGC. SO..you're good to go!

Also, the range of sizes for the clips appear to be rated like 14-16 range, and I would think that they would be good!
T.C.

[DeanR]

The fuses I got fit and look right, but they say ATO. not ATC.
Are the the same thing?

[TopCatGr58]

How thick is your cable?

Hey Dean,

The ATC fuses are correct! They are full sized, not the MINI fuses!

I tried finding my 1/4" female clips, but couldn't find the box. The turn signal wire looks pretty thick, possibly 14ga, I think the other thinner ones are around 16ga, but don't know for sure, perhaps one of the electrical gurus can chime in?

[DeanR]

Stopped in Pep Boys after work today. They had a littlefuse fuseblock of obvious lesser quality for twice the price.
Couple questions : Are ATO fuses the correct ones; and does anyone know what gauge our wiring is, at the fuseblock, for getting the right slip on connectors?

[motoman]

Yeppers T.C..................I'll flip a coin......or make the change if I'm bored to tears.