Glass to Blade fuses - Defender Source
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  #1  
Old March 2nd, 2014, 07:13 PM
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Glass to Blade fuses

The time has come to replace the old glass fuses for something a bit more modern and easy to find replacements for. I thought I would toss this project write-up on the boards to give members some ideas for when they attempt this on their own. My main goals was to find fuse blocks that were as close to the original size and to limit the amount of cutting required.

Here are the fuse blocks I decided to go with. They are .5mm longer than the previous blocks.
http://www.amazon.com/gp/product/B00...?ie=UTF8&psc=1
or
http://www.delcity.net/store/8!way-A...-Block/p_10823

Here is the only major cutting I required to fit the blocks. This was to allow the mounting tabs to fit. On second attempt, I would not have cut as much and just enough to slide the tabs in.

fuses by andrewblpratt, on Flickr

closer shot

fuses by andrewblpratt, on Flickr

test fit. 4 holes drilled in the bracket for mounting hardware.

fuses by andrewblpratt, on Flickr

I decided to use the provided dust covers and needed to space the blocks back 4mm. I used 6.35mm nylon spacers ground down to ~4mm (all I could find)

fuses by andrewblpratt, on Flickr

Roughly 1mm of clearance between the dust covers and the plastic trim cover.

fuses by andrewblpratt, on Flickr

Disassembled for a few coats of Rust-Oleum Hammered Gray.

fuses by andrewblpratt, on Flickr

Another showing the close clearance.

fuses by andrewblpratt, on Flickr

And finally assembled.

fuses by andrewblpratt, on Flickr



Once I get some free time this week I'll finish this project up and update the post.

Cheers,
Andrew
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  #2  
Old March 3rd, 2014, 01:00 AM
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There is a Genuine Parts fuse block and backing plate available, if anyone is looking to do this the factory way.
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  #3  
Old March 3rd, 2014, 01:27 AM
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Who has the backing plate?
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  #4  
Old March 3rd, 2014, 01:35 AM
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Brian Hall at Defenders Northwest can get the Genuine stuff in. George at RDS sells a "fuse box repair kit" that's just the fuse insert portion and the wire terminals that plug into the back but no backing plate.

Useful thread here:

http://www.defendersource.com/forum/...ad.php?t=30201
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  #5  
Old March 3rd, 2014, 01:49 AM
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I believe these are the needed part numbers. Perhaps someone can correct me if I'm wrong.

PRC4826 - Fuse block
AMR3138 (or) PRC8072 - Bracket - Fuse box
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  #6  
Old March 10th, 2014, 05:52 PM
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Finally got some decent weather over the weekend. I added new .250" quick connectors and everything seems to be working fine. I've got 4 extra bays that will house spare fuses till I add a reverse lamp and dome light.

Project total: $25.



defender by andrewblpratt, on Flickr


defender by andrewblpratt, on Flickr
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  #7  
Old March 10th, 2014, 06:20 PM
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Looks factory, nice job.
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  #8  
Old April 18th, 2014, 07:40 PM
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Nicely done
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  #9  
Old April 21st, 2015, 05:28 PM
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Hey Andy,

How did the wire switchover part go? Did you have enough slack on the wires to clip the old terminals and crimp on the new stuff? I've had the parts for this conversion sitting on the shelf for a few months now, just waiting on the courage to tear into it. Everything works now and I don't want add electrical gremlins where they didn't exist before.
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  #10  
Old April 21st, 2015, 05:34 PM
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Great write up.
I've been trying to get up the courage to do this too but, like Chris, don't want to screw up something that currently works.
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  #11  
Old April 21st, 2015, 06:20 PM
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I did mine a few weeks ago...as long as you have the proper wire stripper, crimper, and connectors and cut one wire, attach the connector and attach to the new terminal....took no time and went together without one issue...
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  #12  
Old April 21st, 2015, 07:03 PM
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So there's enough slack in the wires? Did it feel tight after you cut and re-crimped?
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  #13  
Old April 21st, 2015, 08:34 PM
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There was enough slack, but remember you are cutting right at the connector, stripping only 1/4" off and using new connectors that add about 1/4" so there was no issues at all...took me very little time...The only issue is the weird fuse ratings LR used so you have to go up or down a few amps ....I went down and have not had an issue...
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  #14  
Old April 21st, 2015, 11:30 PM
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Perfect. Thanks.
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  #15  
Old April 23rd, 2015, 01:47 PM
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Sorry for the late reply, but looks like you're sorted now. Been offline in Vegas working for a few weeks.
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