Fuse box panel deckboard removal

[81dmc]

Also, this looks like an original (non-melted) fuse box. The PO replaced the interior, door, and rear lights with LEDs and upgraded the door solenoids. Does it still need to be replaced if original? What causes these to melt?

Attachment 58628
Attachment 58629

Mine melted with nice connections. It all depends on the current draw.

If a fuse is running close to pop amperage, it will get hot and melt. On my car, I had to replace one fuse (forgot which one) with one that is 5 amps higher, but then again, that was after I was done going over the harnesses...

[DMC-81]

~snip~

To get the stock/untrimmed panels out it helps to push the bulkhead panel rearward at the rear tip of the access panel so it can clear the bulkhead panel when you lift the rear edge up. Remove the access panel and cut the rear edge of it back 25mm. Optionally finish the cut edge by sanding it before putting it back in.

Here is the text from ST-23-1-81. It includes a diagram showing where to cut back the 25mm (1in.) section - if you know which edge is the rear then you don't need to see it. Diagram is not posted here.

CATEGORY: TECHNICAL
ATTENTION: ALL DMC DEALERS/SERVICE MANAGERS
SUBJECT: REAR PARCEL SHELF BOARDS RH AND LH
From V.I.N. 2309, to facilitate removal of the rear parcel shelf
boards, 25mm has been cut from the top edge of both boards.
See the diagram below.
This modification may also be made on earlier vehicles.

I have a pre-2309 car, and if you don't want to cut the board, or until you get around to do the job, all you have to do is follow this procedure from the service bulletin:

"To get the stock/untrimmed panels out it helps to push the bulkhead panel rearward at the rear tip of the access panel so it can clear the bulkhead panel when you lift the rear edge up."

In my case, "rearward " meant pushing the panel towards the front of the car, away from the padded carpet on the vertical bulkhead. I also found the carpet interfered with the removal even by following the bolded procedure. However, a gentle compression of the carpet while doing it was the key to success for me.

Since mine is the same as yours, perhaps the PO didn't add foam.

I left my board uncut as I like how snugly it fits now. Like Biff's car though, it just needs a certain trick that only the owner knows.