Extra Fuse Box

[trousersnake01]

I wanted to neaten up some of the extra wiring that I had on the bike. I'm the fourth owner this year so others had added bits throughout its life.

I looked at different options for adding and joining wiring and I think the best auxiliary box out there is a gadget called FUZEBOX, which with postage is about £50 notes.

I couldn't justify paying for one of those fuzeblocks so made one myself.

I bought a fuse holder from halfords and a 30amp fused relay, they were about £5 each. I bought some decent wire, spade connectors and fuses from ebay. I recon the fit cost about £20, but I got great pleasure from knowing I tidied up the wiring and done everything so its safe.


I took a decent feed from the battery + and ran it to the relay and through the relay to the fusebox.

I then controlled the relay using the auxiliary wires of the front. This is the now the only power drain from the auxiliary wires.

On one side of the fuse box I created a buzbar using piggyback spade connectors so it has a live feed to each fuse.

On the other side of the fuse box I was then able to wire all my bits in neatly.

1) Garmin, this comes with loads of cable I had to loose.
2) My new oxford heated grips.
3) A power feed for my HID lamps. (Which have their own relay)
4) And power feed for the stebel horn. ( I fitted a relay for this switched by the bike horn wiring) (The second relay top right in my pictures)

All very easy to do and all prompted by finding that the insulation for the bullet connections for the front auxiliary wires had melted. The old heated grips, garmin and switch wire for the HIDs were all wired directly in to the auxiliary wires, I was lucky I didn't have a fire.
So now the only current coming from the aux wires are going to my new extra fusebox relay to turn the feed on from the battery.

I debated for a while where to put the new fusebox as I was considering access but it takes me 5 minutes to get the side off as I have done it so often now. And to be honest I have never had a fuse blow on me, (touch wood).

I'll try and attach some pictures now.

[trousersnake01]

1) Loads of Garmin wire.
2) New Oxford grips.
3) Stebel horn.
4) Halfords fusebox and 30am fused relay.
5) Fixed in position 30amp fused relay.
6) The fusebox with the buzbar feeding power to each fuse I put in.
7) My first feed going out which was the HID power feed.
8) More or less completed with the horn relay fitted top right.
9) Another overview.

[Lonewolf]

Very creative, not sure I would have the patience to do that.

[trousersnake01]

It did take best part of the day to do

[O.C.]

Great job, and very neat, did you use heat shrink over the connections or are they taped ?

I have a Fuzeblock which I had fitted to a Bavarian ditch pump that I once had, but now its still awaiting installation onto the GTR. mmmmmm must get round to doing that....sometime 

[trousersnake01]

No just tapped them, the fuzeblock is the best thing, it was just the price.

[O.C.]

they are a bit pricey, can't remember what I paid Nippy Normans for mine, it was a while ago

There's also the satisfaction of making up your own...yours looks great     

[Trotters]

Looks good. Did virtualy the same on mine a few weeks back as I was a bit worried about having a number of accesories all attached to one auxilary wire. Took me a few days though working between the showers as have no garage to work in. As my wife says, it keeps me out of trouble "going outside messing"

[Debs]

Im thinking of doing the same as Rob but on a different scale..

Was thinking of mounting a fuse box in the tool box and running the wires to and from it..  Already decided to run different coloured wires from it so I know which is which http://www.ebay.co.uk/itm/150969986755?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649

But what I need to know is.... What Amperage do I need to run from the battery to the fuse box? Was thinking of maybe 30 amp.. Any idea or suggestions accepted. 

This is what I want to mount.... http://www.ebay.co.uk/itm/180817893827?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2648

I will measure the tool box when back at home to see if it will fit 

[Kwikasfuki]

Mine had a 30amp inline fuse.

[Debs]

Mine had a 30amp inline fuse.

I mean what gauge wire should I run from the battery to the fuse box? Was thinking maybe 8 Gauge?

[O.C.]

Debs, I'm no sparky, but I reckon the gauge of feed cable will depend upon what accessories, and resulting amperage draw you plan to run from the newly installed fuse box.

Others on here who are more experienced with electrics will advise you better

p.s there's a lot of cable on those drums, are you planning to wire anything else up ....maybe some extra Christmas lights 

[Kwikasfuki]

I mean what gauge wire should I run from the battery to the fuse box? Was thinking maybe 8 Gauge?

This might help: http://www.powerstream.com/Wire_Size.htm

I just got one that looked fairly substantial and used that

[Debs]

I intend to run my Oxford Hot Hand Grips, Spot Lights, Sat Nav, DAB Radio, Air Horn, Phone Charger all through it instead of the set up I have (A big bundle of wires held together with a zip clip)

My aim is to run a wire, maybe this....

http://www.ebay.co.uk/itm/160918864804?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649

to a connecting plug

http://www.ebay.co.uk/itm/321035773702?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649

then to the fuse box mounted in the tool box

http://www.ebay.co.uk/itm/180817893827?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649

then run 8 different coloured wires from the fuse box to this

http://www.ebay.co.uk/itm/140769605228?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2648

then on to the front of the bike where they will be in a rubber boot to be connected to these

http://www.ebay.co.uk/itm/Motorcycle-Bullet-Connector-3-9mm-Male-Female-Japanese-Socket-Classic-Terminal-/170711501780?pt=UK_Motorcycle_Parts&hash=item27bf32cbd4

and then to these

http://www.ebay.co.uk/itm/140895601562?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649

The reason for the plugs at the tool box end is so that it can be un-pluged and removed if need be.

Is this over kill or over engineering a situation? I dont think so.. Its just making the electrical system safer rather than overloading existing circuits.. 

A big reason why I want it n the tool box, is if a fuse blows its easier to lift the seat than to take panels off.

Sound a bit OTT dont it.. 

[O.C.]

I reckon you've just about got it all covered there Debs, I'm sure you have a soldering iron as I would recommend soldered connections as they are better and more permanent, and you'll nee some of this to finish the job off

http://www.ebay.co.uk/itm/Black-Heat-Shrink-Tube-Sleeve-Various-Sizes-Lengths-/160809668245?pt=UK_BOI_Electrical_Components_Supplies_ET&var=&hash=item257100ce95

Good luck and don't forget to post pics as you progress