520H WHS Fuse Block Install

Been meaning to do this for a long time. I'm doing one for a customer today so thought I would get some pics and make this tutorial for anyone who may need it.

The fuse block being installed is the one we make and can be found here - WHS Fuse Block Assy

The original fuse blocks are terribly trouble prone for bad connections. Part of the problem is they are not covered, the other part is the buss bar that they used to feed both the 30A and 25A fuses. There is a lot heat generated in that area from the buss bar connection that they used and we all know what heat does to spade type terminals. To eliminate this the fuse blocks that we make have separate 12 gauge wires feeding each fuse.

** DO NOT CUT ANY WIRES YET.** What makes wiring easy and trouble free is DOING 1 AT A TIME if possible.

I use nylon seamless crimp caps for connectors. They hold more wire length and the wires can be twisted before crimping making a better connection. I also heat shrink everything but it is not necessary if there is no wire exposed at the end of the cap.

Start out by lining up the fuse blocks, there is a smooth side and a side with protrusions so you can piggyback them together. There are also only 3 fuses so the empty slots should be on the same end. As I said, our fuse block does not have the buss bar installed so we have to do things a little different. The next step is simple, connect the 2 feeds to the 1st 2 fuses in the new block to the single hot wire in the old block.

The rest is easy, just cut and connect the same spot in the original block and connect to the same spot in the new block. Some only have 1 wire per terminal, some have 2 in the original block. The main thing is to just do 1 spot at a time.

Once finished wire tie all of the wires together behind your connections. You can also use 1" heat shrink over all of them for extra protection and to keep them together. The extra wire can be formed into an S so they will fit under the fuse block bracket easily. When installing the bracket take care to not pinch any of the wires under it between the metal.

Make a final check after the fuse block is installed and make sure no wires are pinched anywhere. Also check underneath the block where you see the wires come out of the fuse block and make sure they are all free, see the 1st pic.

The fuse block wire connections are all under the fuse block bracket. The other large heat shrink covering wires to the rear of the fuse block in the pics go to the ignition switch, that was done today also but that is another tutorial lol.

nice job and glad my 416 dont have that many wires to worry about..........

Nice tutorial Gene, The fuse box and 9 pin connectors are the electrical weak spots on the 520H for sure.

Well done,

Kurt