AUXILIARY FUSEBOXES & BRIDGES

Sometimes the original fusebox in a car is not enough. It may be more convenient if a set of fuses were located elswhere than the car designers put the original 'box. (Especially headlights) Thats where these fuseholders/boxes fit in.

THE WIRE BRIDGE
When you're installing a new fusebox (Hella 8JD 005 993-001), all five input terminals must be connected to the alternator or battery. Connecting five thick wires to the battery makes quite a mess.
This is where the wire bridge comes in. I stumbled upon it by pure accident, poking around in a scrapyard. At the front inner wing of most Volvo 240's there's a bracket with the lights-relay and a black plastic box with two 9,5mm and six 6,3 mm terminals. All bridged together! Install this wire bridge next to the fusebox, and connect wires from the two 9,5mm terminals to the battery. Nice and tidy.

MATING THE BRIDGE TO A FUSEBOX
-Find a brick, uh sorry, Volvo 240. If you're lucky, it's got the right type of bridge. If not, keep searching.
-At the left inner wing, unbolt the rail which holds the bridge and the headlights relay. Cut the wires.
-Grab the headlights relay firmly and wiggle it off. The sheetmetal bracket will breake at exactly the right spot.
-Unbolt the remainings of the bracket, and straighten it in a vice.
-Cut the bracket in two halves.
-Bend the two halves 90 degrees, and cut a notch so the bridge-lid will fit.
-temporarily screw them to the bridge.
Bring in the fusebox.
-Hold the 'box in position and mark where to drill.
-Drill a 3mm hole in each bracket-half, and find suited screws.
-Cut off excessive material from the brackets.
Fetch the wire-shoe kit.
-Make five short 6 mm² pieces of wire with shoes in each end.
-One end must be insulated. Use schrink-tube.
-Using these wires, connect five of the bridge-terminals to the five fusebox input-terminals.

A donor car	Unbolt the rail	Wiggle...	...until it snaps	Straighten in a vice
Cut in two	Bend and cut	Temporarily fit brack.	Bring the 'box, mark	...and drill
Trim brackets	Wires	Schrink-tube	Connecting...	Connected.

Fusebox/bridge location
The rail is a bit long and may need to be shortened, if it's only for the fusebox/bridge assembly. Also, limited available space in the engine-bay may force you to trim the rail. However, you may also consider attaching a few relay-sockets to the rail. All components in one place makes a tidy installation.
Once the location has been decided, it's time to connect the bridge to a power supply.
-Run two 6mm2 wires from the bridge input terminals to either the battery or the alternator
(depending on which is closest).
-For protection (and tidyness), put them in a tube.

Shortened rail	With sockets. Tidy.	With kit	Connect	Tube

TO BE VERY MUCH CONTINUED...