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Old 02-22-2006   #1 (permalink)
Detritus Maximus
 
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Unanswered: Add-on Fuse box Solution for Headlight Rewiring

I was reminded of this little discovery in another thread tonight....

I was going to post a pic of the latest, greatest problem solver that I never noticed because it was staring at me in the face for several years....unfortunately I can't find the item in question at the moment. I will post a pic as soon as possible.

The issue I had rewiring the headlights was the power supply from the battery for two separate fused circuits for the headlights (one low beam and one high beam) plus a third for the driving lights. It's pretty simple to get the different feeds and install fuses and relays, however, it's not the cleanest installation.
I looked at most of the available add-on fuse panels (One power feed from the battery into the add-on fuse panel, several individual fused circuits going out), but they were either too expensive, too small, or not really made for being under the hood.
What to do?
Well, the answer I found is so simple, so cheap, and so perfect. I have as my daily driver an '87 Mazda RX7. I have accumulated a sizeable collection of spare parts, although not nearly as many as I have for the Opel. In amongst some parts I was sorting recently was the main fuse box. This is a nifty little item mounted under the hood, just in front of the driver's side strut tower, near the battery. It is about 6" long and 1.25" wide, has two mounting bosses that raise it up to clear the wires coming in from under it, plus an optional metal bracket. It has nice little cover that snaps over it and has a main feed on ones side, a main fuse and several (5 or 6) fused circuits. It uses the large plastic fuses, not the little blade type. It can carry alot of amps, too. The under side has male spade terminals (headlight terminal size, not 1/4"), so you can just plug rigth into it.
It's tough, it's got plenty of room, it's easy to install, and it's CHEAP at the junkyard.
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Old 03-27-2006   #2 (permalink)
Detritus Maximus
 
Join Date: Jul 2002
Location: St. Louis MO
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Okay, it's only been a month....I was cleaning my garage and finally found the silly fuse box I was talking about.

It uses fuse type ALF, which start off at 20 amps and go up to 100 amps, and are very common in 80's-90's Japanese cars. There are six available slots and it has a bolt-in 80A main fuse (used for the chassis supply, probably not applicable to an Opel). The main power feed bolts to one lug of the main fuse and the attached buss bar that feeds all the fuses. One large wire in, then each fused circuit has it's own wire going out to whatever accessory it feeds. Each circuit feed is a large male blade terminal, like on a headlight, so you can use 10g wire.

I has a nice little black cover, too. The one I have is from an 87 Mazda RX7. What I do not have in any of the pics is the metal mounting bracket.
The best part is that it is generally very cheap, with bracket, wiring pigtail (cut the harness but leave it attached, this gives you some wiring pigtails to splice to instead of buying overpriced 3/8" female terminals), and some fuses.

I figure the six slots provide for headlights (separate hi and lo fuses), driving/fog lights, stereo, fuel injection, a/c, electric fan, or ?

I have pics in member's album.
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