• Welcome to the new NAXJA Forum! If your password does not work, please use "Forgot your password?" link on the log-in page. Please feel free to reach out to [email protected] if we can provide any assistance.

Wiring an auxillary Fuse Panel

jeepsrock

NAXJA Forum User
Location
LA California
I need to wire in an auxillary fuse panel somewhere in the hood area to clean up the mess on the positive battery terminal. I already purchased a buss 8 fuse panel. I am hoping to use this to connect my hella lights as well as my cb radio.
Panel specs:
http://www.bussmann.com/library/bifs/15600.PDF

It says 30A per terminal and Stud input of 100A

Here are my questions:
1. What wire AWG is suitable for the input source, i was thinking 6awg but other suggest 4awg.
2. Can this handle something such as my hella 500 lights ?
3. Would the input wire have to have a fuse or breaker ?
4. Anyone do this and have suggestions and or pics of locations/stuff ?

Thanks
pete
 
Located mine in the pannel by my left foot. opposite side of the stock fuse block. Im running a 4awg. Id rather have it too big than too small.
 
I put the same block on the panel by the driver's left foot in mine. I put a relay on the positive wire from the battery so it's only powered when the jeep is turned on. I did it for interior accessories though, xm and inverter for now, no intention of putting lights to it. I do plan on adding a good set of fog lights but I will build a dedicated wiring system for that. Power to the interior and then back out to the front grill doesn't make much sense.
 
I mounted something similar to the cover of the fuse panel behind the battery, the one with the larger fuses in it.
 
I am thinking the hood is a better place for me ? Anyone got pics of it there ?

It looks like the fender wall area between the battery and hood fuse box is a good place to mount it. I could then run the hella lights to a terminal to it aswell as a pair of wires to the interior of the cab, one for the cb and another for the future.


ohh and what kinda block do u guys suggest for the ground

sound ok ?
Pete
 
Last edited:
Amplus said:
I put a relay on the positive wire from the battery so it's only powered when the jeep is turned on.

I know I am reviving a somewhat dated thread, but....

I'm a noob when it comes to wiring and I have been trying to learn as much as I can, it really is facinating to me. Where do you find a relay rated for something like that? Most all that I have seen are only rated 30A/50A.

Thanks!
 
5-90 said:
If you pillage around, you can find Bosch ISO relays rated for 30/40A, and they also make "power relays" - typically ~75A, but up to 100A should be no trouble. Try a boating supply house - they carry lots of electrical goodies we can use...

Thanks for your help. Great to have knowledgable people like you on these forums.

Bob and Doug rock, eh!
 
Heres some help for you

[SIZE=-1]Wire Gauge[/SIZE]/ [SIZE=-1]Current Flow[/SIZE]

0 awg/ 330 amps

1 awg/ 262 amps

2 awg/ 208 amps

3 awg/ 165 amps

4 awg/ 131 amps

5 awg/ 104 amps

6 awg/ 82 amps

7 awg / 65 amps

8 awg / 52 amps

9 awg / 41 amps

10 awg / 33 amps

11 awg / 26 amps

12 awg / 21 amps

13 awg / 16 amps

14 awg / 13 amps


Wire Gauge / Recommended Maximum Fuse Size
00 awg / 400 amps
0 awg / 325 amps
1 awg / 250 amps
2 awg / 200 amps
4 awg / 125 amps
6 awg / 80 amps
8 awg / 50 amps
10 awg/ 30 amps
12 awg / 20 amps
14 awg / 15 amps
16 awg / 7.5 amps
These are the recommended maximum fuse ratings for the corresponding wire size. Using a smaller fuse than what's recommended here will be perfectly safe. So use this to determine the wire size in, and fuse it. You also said that it was 100 amp in so go with 4awg and use a 125amp fuse, or underdog it and use 6awg and go 80amp fues. Personally I would use a breaker and not a fuse. This way if it pops you can just reset it. Use quality brakers tho. Cheap ones have a high failure rate and do not pop and just catch fire. Just my .03cents

I tried 4 times to straighten the rows out on this list but it keeps pushing them back together. You should be able to figure out whats up there tho......
 
Last edited:
While those are maxima for fuse ratings by wire gage, fuse selection (and wire gage selection) should both be driven by accessory demands, not wire gage sizes.

If I were wiring in a 10A accessory, I'd use 12AWG (21A) and use a 10A fuse.

Also note that "odd-numbered" gage sizes are are difficult to find, with the sole exception of 1AWG. I'm sure they can be found somewhere, but I've not been able to dig them up easily...

There is (or damn well should be - let me know if there is not) an "ampacity" chart in the Tech Archives of my website ("ampacity" = current-carrying capacity, usually used to refer to wire.) Link in sig.
 
^^^ yea "he", not I, needs to add up what he wants to put on each circuit and figure out his load on the whole panel. To over kill your mainline is what he should do and fuse it down to still be able to handle his load. This way the wire will not be overloaded if he decides to run more "higher" amperage loads per circuit. This was meant as a tool to add it all up backwards to get what he needs as a mainline. This is not my first "go-round" with electricity .... AC or DC.

And now that im into it a little further than i wanted to be (since this is not my rig).... here it goes. Since your panel is only capable of handling 100amps go to 4awg wire and fues it only up to 100amps (no greater). I wouldnt take it to 100amps but i do belive that the manufacturer would have actually built it to handle 100amps consitantly.

Now that we are on the subject of upgrading electrical I bring this to you Mr. Kelley. Just to give you a little insight on the world of car audio (and totally not trying to be a dick here either) The upgraded battery supply cables you have designed have been being used for actually quite some time. I bring up the "BIG 3". The big 3 is :

1 battery neg to chassis
2 alt. to battery positive
3 chassis to engine

So this is not a new invention since the wheel. The cables that are used in car audio actually carry (depending on quality of course) quite a bit of load and have very very thin hair like strands also. But I do have this one question for you since you are here, I see no where on your page (and is a nice page at that) for the cables there is no fuse between the alt. and the battery positive. Now this has been the total beating of a dead horse and argued time and time again. The talks have been about the alt. spiking and causing an overload to the battery. Just wondering your insight on the fusing part.

Again this is not an attempt to be rude, disrespectful or the like. Just an informative discussion.

And your page reminds me of BASF.... "we dont make the battery cables we just make them better" LOL
 
Last edited:
PornstaR said:
Now that we are on the subject of upgrading electrical I bring this to you Mr. Kelley. Just to give you a little insight on the world of car audio (and totally not trying to be a dick here either) The upgraded battery supply cables you have designed have been being used for actually quite some time. I bring up the "BIG 3". The big 3 is :

1 battery neg to chassis
2 alt. to battery positive
3 chassis to engine

So this is not a new invention since the wheel. The cables that are used in car audio actually carry (depending on quality of course) quite a bit of load and have very very thin hair like strands also. But I do have this one question for you since you are here, I see no where on your page (and is a nice page at that) for the cables there is no fuse between the alt. and the battery positive. Now this has been the total beating of a dead horse and argued time and time again. The talks have been about the alt. spiking and causing an overload to the battery. Just wondering your insight on the fusing part.

Again this is not an attempt to be rude, disrespectful or the like. Just an informative discussion.

And your page reminds me of BASF.... "we dont make the battery cables we just make them better" LOL

No trouble with me at all.

To answer your question (In Re: the fuse between alternator and the rest of the vehicle) that's why I offer the ANL retrofit kit - not only to restore fuse protection, but to allow you to upgrade it (if necessary - for, say, a Mean Green 200A alternator.)

Typically, tho, an alternator current spike is caused when the input to the regulator gets shorted to battery supply voltage - I've not seen it happen in years, and most internally-regulated alternators are built to disallow it anyhow. I'd say it's more likely with an externally-regulated unit (old Delco, old Motorola, old Prestolite, Nippondenso, and the like) due to the fact that the field terminals are relatively exposed, and a wire could fall on them. Internally-regulated units commonly use some sort of plastic shelled plug (Molex, Delphi Weatherpack, Deustch, or whatever) to "double-shield" the regulator terminals anyhow - and only a massive wiring fault would cause a short to supply on them. Since the battery mains also tend to be isolated (by design, mainly) from the field terminals, that doubles the protection (if you check the alternator subharness on Chrysler-built XJ's, you'll probably find the mains lead from the alternator bundled in with the two leads for the field coils. Nicht gut - it should be isolated and/or shielded and/or "double covered.")

Typically, the option taken by people would be either ordering the "all except" kits listed (all except the alternator output circuit) and replacing/updating the alternator output later, or getting the "all included" kit with the ANL retrofit installed. Very few people still get the "all included" kit without the ANL - the "two-stage" install is probably more typical.

If you should have any more specific questions, tho, I'd like to keep them backchannel - especially if this starts wandering into "sales talk." It's still "tech talk" for the moment, and I'd like to keep it that way while we're on the boards here (I should probably start a blog page or a small BB for discussion at my site...)
 
I mounted mine on the inner fender. Have all my lights and CB ran to it. Used 4 awg from the battery to the fuse panel.
lights009.jpg
 
Back
Top