DIY - Build and install a Bussmann RTMR Fuse/Relay Block

Thanks, I was about 90% sure.

 

Can anyone recommend an interior connector for 16-14 awg wire? I used Molex Mini for 18-22 but have not found an interior connector for 16-14 awg.

 

Molex .093 series.

 

Awesome. Search results using wire gauge turned up very little. This is perfect.

 

The molex website is pretty good. They also have more robust connectors if you need more juice through the terminals.

 

https://www.easternbeaver.com/Main/Elec__Products/Connectors/connectors.html

 

https://www.customconnectorkits.com/
“SHOWERS” 5% off all weather pack plus free shipping on orders over $25 after discount.

 

Been humming along building my wires and harnesses. Decided to do a test fit to the truck to determine which way I wanted to route my accessory connectors before building them. Damn... the Bussmann collides with my hydraulic hood struts. Did anybody have and solve this problem?

 

Maybe get yourself some 3/4” x 5/16” id bushings and 8 x 30 mm bolts to space the tray off the sidewall more?

 

Hmmm, not a bad idea. I'd have to check and see if that would challenge the support arm and make it not fit. I little bit of Unistrut might do it too. Of course... then it would look like a backyard mechanic did it

But your bushings idea might be the cleaner solution. Can I conclude from your comment, that the thread pattern for the fender wall is 8 x 30?

 

Thread pattern is 8 x 1.25 and I figure you’ll need it about 30 mm long. Edit the plate is ~3mm thick plus a 20mm bushing(~3/4”) is 23mm so 25mm would be too short but if a 1/2” x 5/16” id bushing would work then 25 mm bolts would be long enough. Check both that and how much space you have to the reservoir. Might also help to slide the tray closer to the stock fuse box.

 

There might be just enough room. Wouldn’t want to be up against the reservoir.

 

As mentioned, you could use either rubber or aluminum spacers to solve the problem:

https://www.aluminumspacers.com/

http://www.midatlanticrubber.com/industrial-products/washers-spacers

 

Truth. You might need to trim that side to get enough clearance. Not even sure that 3/4” bushings would be enough with the Bussman cover installed. One other option is a plate that has both holes for the tray and a second set of holes for the 8 mm bolts. That would allow you to lower the position of the tray.

 

@RushT if you need a plate I have some 1/8” scrap aluminum and can knock something out pretty quick. I’d just need to know how much to offset the holes. The minimum offset would be the distance from the CL of the holes in your plate to its top plus another 1/2” or so.

 

Thanks for the offer Bagleboy! I'll look at measurements for that tomorrow. From recollection, the tray slightly overlaps the 3rd gen fuse box so I'm nervous it won't drop much before running out of room. I made some 'variable' spacers with a bunch of 5/16 washers. I ended up with 9/16" before I just cleared the hydraulic strut. But that put me up against the watzamujig handle on the reservoir. So I'm not sure I can make the tray work as is... even with adapters. Powertrays seems like he's willing to help out if a different tray design is needed so that's good to know.

 

The plate could also have front to back offset as well but likely you’ll encroach on the front of the reservoir in that direction as well. I’m sure there’s a solution. Nice that Powertrays is willing to help.

 

If you don’t need all 5 relay slots you can just replace those jumpers needed with more simple fused connectors. You can have as many as 5 relays and 5 fused circuits or just 10 fused circuits with no relays. I wouldn’t buy a Bussman for that but you can certainly put it together that way. The 80A limit still exists though so you’ll still need to figure the total amp draw of all of them that you plan on having on at the same time.

 

I haven’t looked at my spreadsheet in awhile, but I think I’m around 30-35 Amps in lightning once fully done. I agree, I could probably get away with fewer relays, but the Bussmann format still has the same waterproofing cover.

And partly, it was the whole project that was enticing.

Powertrays has been great about it. I sent my current one back and we’re going to work out a viable solution for my setup.

 

Thank you for the bussmann relay thread.