Easy Way to Replace Fuse Box?

[AirmanPika]

OK so I plan to rip out my old fuse box when I can start working on my car again but was curious if there is a suggested easy way to do it. I've only been able to imagine sitting in the back of my car for hours with a way too short amount of wire and cramped conditions.

[Nicholas R]

Whats wrong with your current fuse box? Just curious.

All I can suggest is a LOT of labeling; tape and a magic marker. Keep a wiring diagram (in color if possible) on hand to help out in case you forget or miss something.

[uhhair]

If you find an easy way, please let me know! We did our fuseblock last year and saying it sucked would be a huge understatement. Seriously, it really sucks! Not so much hard, but easily the most tedious and boring work I've ever done on the D.

[AirmanPika]

Whats wrong with your current fuse box? Just curious.

This was taken before I swapped out all the fuses when I first got the car (and another fuse vaporized a hole in the box) but I think you can get the idea

http://reimuchan.com/delorean/fusemonster.jpg

[Bitsyncmaster]

Just start one wire at a time and untangle each wire and you should have plenty of wire length. Yes it's many hours to compleat. Just do about 4 fuses and take a break.

Chose your first wire thinking about how the new fuse block will manuver durring the rework. I think I started with the top right corner.

Defently pull the relay rows and breakers from the mounted positions to get more room to work. I even pulled the metal plate out durring the rework.

[Mike C.]

Good quality labeling tape.
Sharpie
GOOD wire cutters (nail clippers work amazingly in a pinch)
Good pair of wire strippers
A good pair of crimpers that does proper terminal crimps

optional:
Soldering iron
Heat Shrink


Start with #1, remove one terminal at a time, label it. Move onto the second, then the third, etc... until they have all been removed. Take a break.

Install new terminals 1 at a time. If you are anal, you can add some solder and heat shrink as well.

Install starting with the last fuse and work your way back to #1.

Install new fuses, relays, breakers. Start car. Enjoy.


Trust me... remove your passenger seat and sit on a comfortable box. Get a cushion if you can.

[Cory W]

I did mine kneeling on the passenger seat, leaning over the (bolt upright) seatback, with the seat slid forward. Definitely tedious work, but ever so important to the integrity of your electrical system.
I also did one circuit at a time, preventing confusion. Music can be your friend to pass the time here.
Light at the end of the tunnel: You get to go for a drive afterwards.

[1Mcfly4u]

I found it was easier to do it with the passenger seat out, there's much more room

[Bitsyncmaster]

Forgot one tip I found. Don't bother removing the old terminals in the old fuse box. Just clip the wire as close as you can.

[AdmiralSenn]

Clip the wires as close to the terminals as you can. If you absolutely need more room you could consider adding short lengths of wire to the new terminals and then connect the leads to the original harness.

Christine's PO removed the fuse box in favor of tube fuses (unlabeled and the wrong amperage...). The wires were cut really short so I was forced to add wire or the new box would have been completely impossible to install.

Doing this will add another solder joint to the system so I'd refrain from it unless absolutely necessary, and if you DO have to, be sure to make nice clean solid connections on each wire, and don't forget the heatshrink.

[jawn101]

I did a how-to a while back with lots of pics... Here's the link. http://dmctalk.org/showthread.php?t=1070

Short answer is there is no easy way. It's a crap job. But soooooo worth it.

[dmcpom]

one wire at a time, its the best way so no mistakes , and as already said cut close to old fuse box as new terminals you will have :-) I folded and moved the seat to the front although i did get cramp :-)
Andy

[jawn101]

Spending the 2 minutes removing the bolts holding the seat down is time very, very well spent. No question at all. I take them out for almost any interior work actually - doors, under the dashboard, electrical, anything. They're so simple to remove!

[AirmanPika]

Well it helps that I plan to install new carpet anyway so I'll prolly time the two together :)

[orbitron3000]

I've seen a few different vendors selling replacement fuse boxes. Is one better than others? For example, Hervey has one, but it's a bit more expensive than the DMCH version. Does anyone know of any difference between these two, other than the shape / layout? What about quality?

I ask not because the fuse box in my car is melted. No, that'd be too simple apparently. My car's fuses are currently sitting on foam pads.

[Bitsyncmaster]

The DMCH unit has very good terminals. The block is a copy of the original. I've never seen Harvey's so can't compair.

[Spittybug]

http://www.ask-the-electrician.com/images-automotive/car-electrical-fuse-box-inside.jpg
I was thinking of going to Pick a Part and ripping out a fuse panel something like this. Do a total do-over of the passenger side fuse compartment with modern components. Probably just a pipe dream however.................

I too HIGHLY recommend removing the seat before working on this. I also recommend rigging up some good lighting so that you are fussing around with flashlights or other temporary means. SOLDER where possible and put your mind at ease that your connections are solid.

[David T]

If you are thinking about "modern" most new cars have gone to the "mini" fuses. They also have multiple fuse blocks, one in front, one in the dash, under seats, and in the rear. That is probably serious overkill for a Delorean and would require a new wiring harness. One of the problems with the fuse block is it's location. It gets no air so it runs WAY too hot.
David Teitelbaum

[AdmiralSenn]

Hervey's are not stock looking but I think you have a few extra fuse slots to play with on his.

I have the DMCH reproduction and it looks original and works fine.

[Citizen]

Wow, lots of good advice provided in this thread! Way to go guys.

I'd also suggest getting a box (or floor) fan, and aim at the open door area where you'll be working. Put on some tunes, and have you favorite ice-cold beverage of choice handy. Maybe the job will be tedious, but not so bad after all.

Thomas

...

[Morpheus]

If you decide to "get creative" with an aftermarket fuse box on your car, do yourself and any potential future owner a favor and DOCUMENT EVERYTHING.

We had a car come through the shop with a lot of electrical issues, and when we looked in the fuse box we immediately knew why.

52658

Not only did this PO completely re-wire the fusebox area, but he did it badly, and with house wire. It took many many hours of work to make it look like this again:

52659

[louielouie2000]

We had a car come through the shop with a lot of electrical issues, and when we looked in the fuse box we immediately knew why.

52658

I looked at a car earlier this year which had a badly scorched electrical compartment rigged up exactly like that. The thought of undoing all of those extraneous wires, correcting and rerouting them to a new fuse box, and hunting down the source of what caused the fuse box and relays to burn vs melt scared me away from an otherwise very solid car at a fair price.

[David T]

I looked at a car earlier this year which had a badly scorched electrical compartment rigged up exactly like that. The thought of undoing all of those extraneous wires, correcting and rerouting them to a new fuse box, and hunting down the source of what caused the fuse box and relays to burn vs melt scared me away from an otherwise very solid car at a fair price.

Electrical repairs are one area where everyone thinks they can fix it. You see some very "creative" repairs. Sometimes it looks like Jack the Ripper was working on the car. Then there is the rodent damage you typically see in a "Barn Find". Don't forget the stuff that you find when the fuel pump circuit doesn't work so that gets re-wired! The parts and materiel to do the proper repairs is negligible but the time can be excessive! Another area that you find a mess is when there is an after-market alarm. It can take quite a while to dissect it out of the car! On one car I repaired the PO put the wrong relay in the wrong spot. Made a mess under the relays with the burnt wires. Took a while to clean that mess up. Do not underestimate the effort it can take to get things back into proper order. Every owner should make sure you have the proper size fuse in each position of the fuseblock and examine that area once in a while for any signs of heat damage. The cooling fan relays and the fuel pump circuit are notorious for burning up.