Distributing +12V power. Easy, neat and safe designs

[kritip]

Right, I have recently gutted my wiring and moved the battery to the boot. Now its time to wire it all back up.

I have a red top battery in the boot, earthed to the chasis, and a 60mm2 415A cable running from the battery (with a 300A Megafuse in line right up by the battery). This cable then runs down the car to the bulkhead via one of these bulkhead adapters:

image.jpg

To that one M10 bolt I need to run:

Starter
Alternator

Fan (via 40A fuse) -- needs relay

Via the main relay (or several due to current load, all switching from one source)
4 x LS2 coils (via fuse) (8-11A peak current floe EACH when charging)
Fuel Pump
4 X Factory fit and retained circuits (fused 30 to 60A fuses)
Injectors
and probably a few things i have forgotted.

Obviously all those linked up to the one bulkhead adapter isn't going to happen, so how do people manage their power distribution, fusing and relays?! (My relay board died a death of corrosion, and doesn't provide all the outputs i need)

I was thinking about something like this?

S-D-426722-1_med.jpg

Bolting it near the bulkead adapter, and then running all the power to relays and fuses? About the only way i can realistically see doing it. The alternator and starter would go straight to the bulkhead adapter though, due to the hig currents involved.


Am I mad, am I missing a neater or more obvious solution? I worry about the corrosion of the exposed connections, but can't see an alternative. All those seperate power lines from all the devices won't crimp in one connector i doubt and would make modifications to the loom a nightmare.


Cheers for any ideas,

Kristian

[fury fan]

For the most part we're on our own for relay panels.

Here are some pro-grade relay panels:
http://www.tst-corp.com/catalog/power-d ... nters.html

That company is one of 2 I have seen that makes aftermarket automotive relay panels, however they are expensive.

For loose parts, check these guys also:
http://www.delcity.net/store/Relays-&-P ... tion/a_all

I've bought stuff from them to make my own panel. My first panel was too big (made it look out-of-place in the car), so I'm making a smaller version now.

If you do any junkyarding, the Ford Crown Vic police/taxi offers a 2-relay pod on the passengerside fenderwell (complete with mounting bracket) and most 90s-era Lincolns have a 3-relay module underhood. You still have to provide the terminal strips and such, though.