Ultimate Fuse board Solution - Mondial8 328 412 Testarossa

Guido, theunissenguido, in Belgium has duplicated fuse boards for several cars, Mondial, 328, 412, Testarossa and perhaps several more. It basically involves duplicating the board with contacts, and connecting them with 'house' wire. The information was buried but deserves it's own thread. I'm taking the liberty of copying Richards post here:

"Hi,
I just prepared a fusebox that I could buy recently. It whas a fusebox for a Ferrari 412 and I wanted to transform it for a Mondial QV. I just needed the main board so I toke off all the elements like layers, male and female connections. There was only 1 point burned and likely it was a male contact for the radiator fan in the tropics, which I don't need.

The other problem was the bigger special relay for the wiper speed that has 6 contacts, while the 412 uses 2 normal Bosch relays on that place. I solved this problem by drilling 6 little holes in the main board just like the Mondial has. The cover for my Mondial fits normally on this main board to...that holds the big wiper relay in place.

The idea was to replace the (copper) layers by normal wiring...I use 2.5 mm2 (10 ga awg) wiring, which is normal use in house electricity.

To make it more easy I use 3 different colors...
Red for incoming power ;
Blue between the relays and outgoing power ;
Black for the negative wiring.


Taking the fusebox apart is simple. First take of the protection plate in the back (5 screws), take of all screws inside with those little white rings. In front you take of the fuses, and with a screwdriver pull of the 2 plastic protection that covers the fuse-contacts. This is a little sticky. An other way maybe is to unsolder all those contacts first and take the complet cover with contact off.
Take of the front plate and the main board with layers is free for working on it. "
more pictures at http://www.ferrarichat.com/forum/showthread.php?t=209843

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"Paul
Wider traces are not needed. All wires can be soldered by using one or other direction.
Everyone with some soldering skills can build this board. I did get the basic boards as sample for experiences.
Those Bakelite boards are not available like thus...I have to buy a big board from 2 to 3 meters and this Production Industrial plant will cut it to the right dimensions. It will leave me with 35 till 40 basic boards....so if there are others interested in buying a basic board to make there own fusebox...I can consider buying a 2x3 meter board.
I have make myself a metal sheet with the needed holes for all connectors to use it as model...for those who are interested...I can make those holes before shipping them. The holes are in the right places for all relays, fuses and white connectors. For the 2 big yellow copper connectors I bought a small 1 meter copper metal in the local metal store and cut it to the right dimensions.

On 1 picture you can see the differences between old and new pin connectors. The female legs are from 2,5 mm2 copper wire and soldered together. I know..its a time consuming process, but resolved all fusebox problems. Instead of the OM plastic cover I use an aluminum sheet to spread the heat from those relays.
Guido"

Final note by PaulB: In the US, copper clad fiberglass printed circuit board material, is easily obtained and can easily be etched at home. I'm proposing someone can take on this project. I have everything available to expose, etch and drill pcbs in my garage except the vision to accomplish it. I'd be glad to provide advise to anyone willing to go to the next stage. Until then, Guido's solution is certainly quite viable.
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Looks nice! Good to remember that circuit boards replaced point-to point wiring because they are easier and much cheaper to produce in bulk, NOT because printed circuits are better...

Though point-to-point DOES require the willingness to learn proper soldering.

 

The first picture whas the first fusebox I produced with normal wiring. It still has the original connectors and pins.
The latest boards are fitted with the pins and connectors you see on the other picture.
The pictures I make of those newer boards get lost in my pc crash. But it is the same principal..with 2 pins for every connector instead of 1.
The male connectors for the white plastic connector are turned 90 degrees> The white connectors needed to be cut a bit to hold female connectors so they go back in place.

Guido