Copied from here and adding info.
Thanks to SpeedRye from FJCruiser Forums for a detailed build on the 10 Position one.
Originally Posted by SpeedRye
I needed something with at least 8 relays and sPODs are way too expensive in my opinion, especially to buy two of them. I'm not opposed to doing some of the wiring myself. Solution? A Cooper Bussmann RFRM fuse/relay block with room for 10 relays and 40 fuses. It's got two bus bars, so I'll probably do one always hot and the other on-with-ignition. The good news is that this is much more water proof than the sPODs, uses the same mini fuses as the rest of the truck and is much cheaper as well. I shouldn't outgrow this thing anytime soon! I'll update this thread as I build this thing up more.
Relays (ISO 280 Micro relays):
Single Pole, Normally Open (SPNO) - http://www.mouser.com/Search/Product...-3011ASR112VDC
Single Pole, Double Throw (SPDT) - http://www.mouser.com/Search/Product...1-1C-S-R1-12VD
Fuses (ATM Mini Blade fuses):
Available everywhere from auto parts stores to Walmart - http://www.amazon.com/Bussmann-NO-43...rds=mini+fuses
Connectors & Terminals(Delphi Packard 280 Series):
Terminals come from the Delphi Packard 280 Series Metri-Pack line. They come in male and female and each is dependent on the wiring gauge that you're using. The cavity plugs are the same way and come in different colors per wire gauge. The colors are hard to find corresponding wire gauges for, but I believe this is correct:
12 gauge = Blue
14-16 gauge = Gray
16-18 gauge = Green
18-20 gauge = Tan
20-22 gauge = Purple
22-24 gauge = Red
Install is simple. You slide a cavity plug on the wire you're connecting. Crimp the male or female terminal to the wire. I soldered mine after this as an added precaution. Slide the terminal in to the connector or housing until it clicks in place. Slide the cavity plug along the wire until it's plugging the cavity at the back of the housing or connector. Done. Repeat as needed.
Female terminals plug in to the rear of the main fuse box housing. Male and female terminals are used on male and female connectors. Order as needed.
Many of the connectors, plugs and terminals need to be bought in multiples since that's how supply houses sell them. You're likely to end up with some extras. Being that these items are small, the shipping isn't too bad, but most supply houses do charge a handling fee to pick out 10 of item X, 20 of item Y, 50 of item Z, etc.
So far, I've purchased all of my items from Waytek, but there are other places. Here are a few links for sales and references:
If you want to get all fancy and spend some extra money: http://www.amazon.com/gp/product/B00...ls_o03_s00_i00
As you can see in my later posts, I'm using some connectors to make removal and rewiring easier if needed in the future. I already had a bunch or wire around the garage, so you might need to purchase some wire for your project. The more colors, the better. You can use each color of wire to represent something. For my lighting, I'm using red for 12v+ to battery, black for 12v- to ground, blue for 12v+ signal from switch and white for 12v+ to lights. You get the idea.
The Bussmann box that I'm using has two main bus bars and I've decided that I won't need 40 circuits for power, so I'm choosing to use one bar for power and the other for ground. Each bar connects to 20 of the fuses. Because of this and the fact that I can't find mini fuse jumpers, I'm just going to use matching fuses on power and ground sides, so my wiring will end up ground in two places.
I'm choosing to run 4 gauge power wire and ground to the fuse box since I had some around. There will be an in-line fuse at the battery. There will also be a high amperage relay in-line (aka battery isolator) so that my fuse box only has power when the ignition switch is turned to accessory. I got a great deal on the PAC 200 isolator from Chris on the forum here, so I'll use it and see how it does. http://www.sonicelectronix.com/item_...C-PAC-200.html It's probably overkill, but that shouldn't be a problem.
I'm not 100% sure how I'll mount the fuse box yet, but it'll be near the stock one, up high. There's an enormous amount of space between the stock fuse box, brake master cylinder and the hood, so it'll end up in there somehow.
More info as posted by Soonenough in post #129 :
METRI-PACK SEALED 280 CONNECTOR PART NUMBERS
These are all the OEM Delphi part numbers for the various Metri-Pack Sealed 280 connectors, terminals, cable seals, etc. I have listed the P/Ns and quantities you would need to order to make a complete mated connector (male and female halves); the only other thing you need is wire and a crimping tool. Each vendor will likely have their own P/Ns for these parts, but you should always be able to reference the Delphi P/N. Disclaimer: I take no responsibility for this list being correct. This is simply information I've found online. If you find an error on this list, post it or PM me and I'll make the corrections.
1. Temp Rating: -40ºC - 125ºC (-40ºF - 257ºF)
2. Current Rating: 30A (this is the total rating for the entire connector, NOT per wire)
3. The 1-wire and 2-wire connectors use the same TPA Lock (the part that snaps onto the back of the connector body to hold the wires / terminals / cable seals in place inside the connector body), whereas the 3-, 4-, and 5-wire connectors have two different TPAs - one for the male connector, and one for the female connector
4. The wire gauges listed for the cable seals are not absolutes. Different wires have different insulation thicknesses, so a wire seal nominally for 16-ga might work well on 14-ga with thin insulation, or 18-ga with thick insulation. It's up to the installer to ensure the cable seal has enough 'squeeze' onto the insulation OD of the wire.
(qty 1) Connector Assy, Male - Delphi P/N 12065171
(qty 1) Connector Assy, Female - Delphi P/N 12065172
(qty 2) TPA Lock - Delphi P/N 12065249
(qty 1) Terminal, Male - choose from list below based on wire gauge
(qty 1) Terminal, Female - choose from list below based on wire gauge
(qty 2) Cable Seal - choose from list below based on wire gauge
(qty 1) Connector Assy, Male - Delphi P/N 15300002
(qty 1) Connector Assy, Female - Delphi P/N 15300027
(qty 2) TPA Lock - Delphi P/N 15300014
(qty 2) Terminal, Male - choose from list below based on wire gauge
(qty 2) Terminal, Female - choose from list below based on wire gauge
(qty 4) Cable Seal - choose from list below based on wire gauge
(qty 1) Connector Assy, Male - Delphi P/N 15300003
(qty 1) Connector Assy, Female - Delphi P/N 12040977
(qty 1) TPA Lock, Male - Delphi P/N 15300015
(qty 1) TPA Lock, Female - Delphi P/N 12034145
(qty 3) Terminal, Male - choose from list below based on wire gauge
(qty 3) Terminal, Female - choose from list below based on wire gauge
(qty 6) Cable Seal - choose from list below based on wire gauge
(qty 1) Connector Assy, Male - Delphi P/N 12129600
(qty 1) Connector Assy, Female - Delphi P/N 12129565
(qty 1) TPA Lock, Male - Delphi P/N 15324063
(qty 1) TPA Lock, Female - Delphi P/N 15300016
(qty 4) Terminal, Male - choose from list below based on wire gauge
(qty 4) Terminal, Female - choose from list below based on wire gauge
(qty 8) Cable Seal - choose from list below based on wire gauge
(qty 1) Connector Assy, Male - Delphi P/N 12186400
(qty 1) Connector Assy, Female - Delphi P/N 12084891
(qty 1) TPA Lock, Male - Delphi P/N 12084673
(qty 1) TPA Lock, Female - Delphi P/N 15324857
(qty 5) Terminal, Male - choose from list below based on wire gauge
(qty 5) Terminal, Female - choose from list below based on wire gauge
(qty 10) Cable Seal - choose from list below based on wire gauge
TERMINALS (tanged, not tangless)
Male 10-12 ga. - Delphi P/N 12048254
Male 12-14 ga. - Delphi P/N 12129497
Male 16-18 ga. - Delphi P/N 12048159
Male 20-22 ga. - Delphi P/N 12124977
Female 10-12 ga. - Delphi P/N 12077413
Female 12-14 ga. - Delphi P/N 12129493
Female 16-18 ga. - Delphi P/N 12077411
Female 20-22 ga. - Delphi P/N 12084201
CABLE SEALS / CAVITY PLUGS (note: Delphi has old and new P/Ns for some of these parts; old P/N is listed first [12xxxxxx] followed by new P/N [15xxxxxx] )
12 ga. - Delphi P/N 12015193 / 15324981 (blue color, for insulation OD 3.45-4.30mm)
14-16 ga. - Delphi P/N 12010293 / 15324980 (gray color, for insulation OD 2.81-3.49mm)
18-20 ga. - Delphi P/N 12015323 / 15324982 (green color, for insulation OD 2.03-2.85mm)
20-22 ga. - Delphi P/N 12015899 / 15324983 (red color, for insulation OD 1.29-1.70mm)
Cavity Plug - Delphi P/N 12010300 (green color)
20-24 ga. - Delphi P/N 12089679 (purple color, for insulation OD 1.60-2.15mm) *not commonly used
18-20 ga. - Delphi P/N 12041351 (tan color, for insulation OD 2.03-2.42mm) *not commonly used; covers same range as green seal, no reason to use this
TERMINAL REMOVAL TOOL
Delphi P/N 12094429 (green handle)