So after adding multiple add-on accessories to the Jeep over the past four years, things were starting to get out of hand. The stubs on the PDC were starting to look like a rats nest after adding OBA, Taurus fan, lights, and HD headlamp wiring. So I decided to add an AUX fuse block and relay block.
I started looking around the local junk yards for the fuse block that I wanted. I was looking for something that held around 8 MAXI fuses. I used a fuse block from a early 90’s Buick Park Avenue and a fuse block from a 97 Pontiac Grand Am. Between the two fuse blocks I was able to make one that I want. The fuse block use Delphi Metri-Pack 800 series terminals.
Fuse Block from the Grand Am
One of the two Buick Fuse blocks
I took one of the Buick fuse blocks and used the mount from the grand am fuse panel. I also removed all the wires from the Buick panel and replaced them with all 10ga wires from the other sockets. The pins can be removed with a small screwdriver.
I mounted the fuse block on the passenger fender just in front of the factory PDC. Each fuse on fuse block will feed a relay. The relays are mounted on the fender as well. I used interlocking relay holders. These relay holders and terminals can be found at
www.waytekwire.com. The fuse block was connected to the battery with a 4ga cable that is roughly 3ft long.
For the fan I am using standard Bosch 40 amp relays and 40 amp Maxi fuses. After reading this article in the last JP magazine about how much current the fan actually draws. I started with a 20 amp fuse and connected the fan with the fuse directly to the battery. The 20 amp fuse popped on the low speed setting after about 1 ½ minutes. So I tried it with a 30 amp. The 30 amp fuse held up for 10 minutes on both high speed and low speed with out failing. However, the fuse was getting kind of warm on the high speed. So I used 40 amp fuses and relays to be safe. I previously was using a 40 amp fuse and relay for the low speed fan for over 2 years with no issues.
JP Magazine - July 2010 Randy's Electrical Corner
I'll probably post some more pics and some wiring diagrams later on.
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1992 YJ 4.0L, AX-15, 4" RE Standard Lift, 35x12.5R15 BFG KM2's, 8.8 Rear, HP30 front, 4.10's, SYE and CV Driveshaft, Taurus Electric Fan, 136 A GC Alternator, Grand Prix Seats, RR HD Steering, JCR Off road Stage 2 Front Bumper, Custom Rear Bumper
1966 M416 1/4 Ton Cargo Trailer -- Build Thread
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Adding and AUX Fuse block and Relay Block
Great job. It looks clean.
