Power distribution??

[speED]

Curious to know what some of you guys with older vehicles have done in order to meet your vehicles electrical needs. Stock fuse boxes can not handle the variety of accessories some of us are adding: power windows, power seats, electric fans, and the list goes on.

Thanks,
ED

[nedhed]

Just saw a cool article in Hotrod Magazine about a new wiring system from Isis power systems. Really cool. Check it out.

http://www.isispower.com/

[69importkilla]

ISIS!!! If you're wallet can handle it...Otherwise the newer wiring harness out there can hold up to probably anything you could throw at it

[speED]

I also read the article on ISIS, very cool. There is something about not having a wiring harness that bothers me. Also very expensive.

69importkilla: I assume you are talking about harnesses from company's like PAINLESS.

[OhioProto]

there are plenty of ways to piece it together if you know EXACTLY how many circuits you'll need...but even then one of (insert brand here)'s kits will probably end up cheaper.

[MonzaRacer]

Ok several ways to add power in different areas. Looking around junkyards you can find many mounted stud power take offs, I will simply add a maxi fuse block near the battery then take off a 6, 8 or 10 ga wire from that to the stud, then you can use fuse holders or fuse link wire to certain circuits too.
Then you can pull power for different items in different places. Heck I have even mount them under the dash out of harms way.
I crimp, solder and shrink tube the connections. You can also use the Maxi fuses like some fords ran some run up as high a 125-175 amps, enough for a big amp(s), accessories, and add on equipment.
Big idea is to make sure the powered connection is protected, say the stud gets a colored vinyl vacuum cap, or cover. Small project boxes can be had from electronics stores and catalogs and hold the fuse safely. And also remember never fuse a wire with a smaller fuse at battery then larger for the option, and make sure your cable is big enough to handle the AMPs the fuse is rated at.
Good rule I go by is this, 10ga = 50-60amps max, 8ga=60-80 amps max, 6ga= 90-125, and 4 ga= 175. If you use more than 2 connections then up your feed wire to next gauge.
You can also get some sweet brass power blocks from stereo installers and just run big fused cable to it then pull smaller power from that.
Say use a 175amp maxi fuse from a Ford under hood, then run 4 ga cable (get a good hammer type crimper) you can use the pretty stereo cable and gold terminals and colored shrink tubing to clean up after a crimp.
I will also use my torch to add security with a little solder too, before I use the blocks allen screw to secure it l will solder the cable end solid THEN insert into the block.
The possibilities are endless and many, just fuse everything.
Ill dig up some old stuff I have done/used and take pics when I find them.

[speED]

MonzaRacer,

Thanks for all the info. I recently found a buss bar which contains 8 fuse holders and 6 ground connections which I think will be perfect for what I'm looking to do. I would still appreciate seeing some pics if possible of past projects.

Thanks,
ED

[TnBlkC230WZ]

You can also build your own fuse panel
This is a standard Delphi electrical center. You can get most of the parts, except one and it will easily handle 250 amps. The external 60 amp relays switch the Ign, Acc, Hi fan and starter solenoid. The entire ignition switch uses less than one amp. The best part is it mounts under the hood

[bigblockcamino]

In the process of Pain-in-the-@ssLess install on mine. I don't recommend it at all. Could have done it for 1/3 of the price with bunch of 10/12/18 wire and a new fuse block.

[MonzaRacer]

Yeah I tend to rip shtuff out of junk cars or use stereo stuff where its not applied, but hey as long as it works and is fused! I could care less.

[digitalman2112]

You can also build your own fuse panel
This is a standard Delphi electrical center. You can get most of the parts, except one and it will easily handle 250 amps. The external 60 amp relays switch the Ign, Acc, Hi fan and starter solenoid. The entire ignition switch uses less than one amp. The best part is it mounts under the hood

I really like that panel - How did you source it? Any specific model or year to go after?

[wmhjr]

I think it all depends on what you're doing. I am currently in the process of wiring my project using a Highway kit from American Auto Wire. It's a well thought out generic kit, well labeled, and most importantly it has a very compact fuse box assembly. Since I'm not using any type of factory harness, wanted to put the fuse box in the glove box with the MSD ignition, and am hiding almost all of the wiring, a setup like this was perfect. Add a couple enclosed power distribution blocks from Ron Francis, and I'm all set. None of the "non factory" kits are delivered completely ready, because they're designed to use in multiple applications. I'm very satisfied with my AAW setup.

[TnBlkC230WZ]

I really like that panel - How did you source it? Any specific model or year to go after?

Not sure what cars it might be in. The parts are cheap enough that I bought them all new. If you got it out of a car, you'd need to change most of the terminals to suite your needs anyway. The top cover, bottom cover and actual panel are about $25 new. The relays are about $5.50 each. You could steel them from a newer GM car. Look for the Omron's. They have a 100A surge rating.

You are going to spend $50 on terminals reguardless of wether you get a new on or used one. You can't reuse them and if you cut it out of a donor car, they will be useless. the most you could save on a used one is about $30.

There is only one part I couldn't get unless I wanted 168 othem and that was the stud buss assembly. You loose the two front maxi fuses without it. If anyone finds it, let me know.

I got all the parts from www.mouser.com. There are other sources, but most of them have minimums on the quantities. Here is a link to the GM catolog. Look in the electrical center section. There are lots of options. This is the one I choose. It's actual size is about 4.5*7.5 inches.

http://delphi.com/pdf/contact/brochu...balCatalog.pdf

[digitalman2112]

I got all the parts from www.mouser.com. There are other sources, but most of them have minimums on the quantities. Here is a link to the GM catolog. Look in the electrical center section. There are lots of options. This is the one I choose. It's actual size is about 4.5*7.5 inches.

http://delphi.com/pdf/contact/brochu...balCatalog.pdf

Awesome, thanks for all the details!

[TnBlkC230WZ]

As I thought more about it, if you find one in the bone yard, just make sure it uses Metri Pack 280 buss bar and Metri Pack 800 terminals. The 800 buss bar will probably be reusable.

[H2Ogbodies]

I wired an entire electrical add-on harness for a 66 Chevelle that is primarily drag race...(Mark VIII fan, 2 Edelbrock fuel pumps, nitrous/fuel solenoids, trans brake solenoid, line loc, master arm switch, cooling fan over-ride switch, purge solenoid, trans cooler fan, headlights) from a fuse/relay panel from an LT1 Camaro. Look for it on the drivers side inner fender-it's small and has enough room to runa lot of stuff, as just listed! I swapped to a GM style serpentine, changed over to a 140 amp alternator, updated the charging system wiring, etc. and this car has a ton of voltage on tap and all of it is fuse protected through relays and it is all neatly labelled both under the fuse/relay cover and on the relays themselves. I just bought new terminals from NAPA and re-wired it as needed. The guy I was building this car for freaked out at the site of about 18 different rolls of automotive Delphi spools on a custom cart I made just for this sort of thing. I drew a master diagram and started pulling wires for circuits-i prolly had about 75 wires running to my termination table from my spool cart right in front of his car! All I could do was give me my "don't worry, I got this under control...." look-he never seen anybody wire a car like that before. I used to be an electrician for 6 years. My advice is to look at GM-they have the best designed fuse panels imo. I have an account for Delphi stuff so it's no biggie for me. But anywho, hit up the junkyard for LT1 cars...they have awesome relay/fuse panels!!

[TnBlkC230WZ]

Do you have a pic of the Camaro Fuse Panel?

[H2Ogbodies]

I do...let me check my project folders and I'll post a couple pics up...

[TnBlkC230WZ]

Thanks. There is one part I need for mine that I can't get unless I order 126 of them.