Aux Fuse Block Install (with clutch fluid reservoir)

As part of the preparation for installing a LED light bar, I installed a aux fuse block in my 2016 3rd Gen today. I went simple with a Blue Sea 12 circuit ST Blade fuse block. I really like the features of the Bussman RTMR fuse blocks, but it seemed like overkill for my needs of running a few lights and radios. I have run the Blue Sea fuse block on my 2006 for 200k + miles in all conditions without any issues.

Because locating the fuse block on the drivers side of a manual transmission truck is complicated by the clutch fluid reservoir, I followed a similar approach as I used on my 2006 2nd Gen back in 2011 which is discussed in this thread:

https://www.tacomaworld.com/threads/aux-fuse-block-install-with-separate-clutch-reservoir.152254/

Many people on TW have made similar fuse block installations long before I did. Mine is a bit different because of the clutch reservoir. The 3rd Gen layout and dimensions are slightly different, so I made a few minor modifications to the design I had used for the 2nd Gen. I used 0.125" 5054 Aluminum sheet for this mounting panel whereas I had used 0.062" sheet for the 2nd Gen panel. The thickness matters very little.

Here is the fuse block I used:

$41 Blue Sea Systems 5026 ST Blade Fuse Block 12 Circuit with Ground and Cover

http://www.amazon.com/gp/product/B001P6FTHC

Here is the 100A breaker I used:

$71 Blue Sea Systems 7144 187-Series Circuit Breaker, Surface Mount, 100A

http://www.amazon.com/gp/product/B000KOTALG

this breaker is overkill for this application, and there are cheaper options available, but I like the ability to easily throw a lever switch to kill power when needed.

 

What equipment do you use to bend your metal sheets?

 

On this one (with thicker sheet) a had a friend that has a nice brake do it. On the thinner sheet for the 2nd Gen, I used a vise.

 

Thanks. I'm trying to fab something myself, but don't have the tools to do a proper bend.

 

Damn that's nice. Wanna make another one of those mounting panels?

 

Thanks. No, don't have enough time as it is.

 

what gauge are you using

 

I used 0.125" Aluminum, which I do not believe has a gauge designation. Any sheet stiff enough to hold the lightweight breaker and fuse block could be used.

 

Make sure you do not use a 6000 series Aluminum or it will break when you bend it.

 

Looking good. With this type of set up where will you mount your relays?

 

Relays mounted behind breaker toward firewall.

 

So are they on the bottom of your aluminum piece or mounted to the firewall? I took a different approach with my aux fuse block so I am curious to see how others are doing it. Thanks.

 

Link ?

 

Relays can be mounted on the bottom, but since I only need a few, I will mount them out of the way in these areas.

 

https://www.tacomaworld.com/threads/wiring-an-aux-fuse-block-relays-and-switches-in-a-2016.401253/

 

Nice work!

 

I like the "color matching" too. Nice work. Did something similar on my 4runner

 

Aux fuse block with Northstar AGM battery.

 

Any chance you might be willing to share the dimensions of your plate?

 

Clean install.