Wiring Protection Modification
For Zephyrs
By Karl Schluter
(Low Zep)
MkIII
Zephyr and Zodiac cars do not come stock with a fuse box,(Note: This applies to
MkI’s and MkII’s also), so I have developed a method below that fits in minutes
with little work, no drilling and NO cutting of any factory wires. It can also
be removed later or transferred to another car, with the original car returned
to standard. It could also be used on more than just our Mklll model of cars.
Some aftermarket
wiring companies and factory manufactories use fusible links, these are short
inline sections of wire mostly installed in the main harness near the battery,
that are designed to melt and disconnect thus stopping power going through the
cable in the event of a dead short. The idea is once the fusible link blows,
you then have to trace and repair the fault instead of just replacing a fuse.
However you can be stranded on the side of the road and you will need tools to
fix the fusible link. Instead some aftermarket companies are now using the MAXI
fuse for protection, these fuses can carry high amperage easy, they can be
replaced if blown in seconds and if need be can be replaced with a different
amperage fuse. However it’s still important to find the fault if your car
continues to blow fuses. I use a 60A fuse, for your own car use one rated about
20% above your alternator or generator to be safe. The idea is for the fuse to
mainly blow in the event of a dead short.
I recommend
a waterproof MAXI fuse holder fitted with at least the same size cable in total
(8AWG) as the two smaller brown factory wires it will bolt/connect too. (These
are the two brown wires crimped together at the factory to a ring terminal and
then connected to one side of the remote starter solenoid).
The MAXI
fuse holder goes inline of the ring terminal holding the twin brown factory
cables and the remote starter solenoid post that before held the above
mentioned twin brown cables ring terminal.
You then
also have a choice of installing a circuit breaker in the same MAXI fuse holder
instead of the push in blade MAXI fuse. These can be reset with the push of a
button, (any good Auto electrical supply shop should be able to order you one
of these). Another plus is the fuse/breaker can be removed from its holder to
help stop a thief as well if the car is unattended over time.
I use the
correct crimping tool to secure the ring terminals at each end of the MAXI fuse
holder, crimping is fine, remember your car came stock with a lot of crimp
terminals! Don’t use side cutters!
If you
prefer solder, let the bare wire continue through the crimp section of the
eyelet a few mm, crimp, and then solder the tip of the wire that’s showing
through the Ring terminal.
I bolted
one (any) end of the MAXI fuse holder to the factory brown twin cable ring
terminal using a brass bolt, two washers and a retaining nut (I use a short
section (50mm) of heat shrink to cover the brass bolt and washers). The other
end of the MAXI fuse holder returns to the solenoid, in the same position the
factory twin brown cable ring terminal did before you removed it. For those of
you in New Zealand and Australia, I found most of my parts at the Super Cheap
chain of stores.
Here are
the important part numbers:
MAXI fuse
Holder # 120450 (8AWG wire)
MAXI 60A
blade fuse # 120414
(The above
are SCA brand).
Crimp Ring
terminals # 120061 Packet (Yellow 8.4mm)
Assorted
brass washers and nuts & bolts, and a short section of heat shrink.
Those who
would prefer one of these made up and sent to them, contact me ( avocalea@clear.net.nz ) for a
price.
Why not
do an Article on your Pride and Joy and have it featured on the home
page or spend an hour doing a technical article about anything you have
done or know of to do with these cars
We need more information for
this site, to make it bigger and better. Any information on these cars will be gratefully
accepted. Paint Codes, Colour Charts, Technical Information, Articles out of a
book or Magazine you might have, Scanned copies of Advertisements, We will
accept just about anything at all to do with these cars. It might seem trivial
to you, but could be information someone has been after for years. Email
anything at all to Karl
Enjoy the Site
Disclaimer: The
advice and guidelines given in these articles are given in good faith. The
owners and managers of the Galeforce Zephyr site will take no
responsibility for any injuries or loss sustained while carrying out the
described tasks and procedures or any consequences arising. Please read
the Safety First Article