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Like many towed vehicles, you must remove several fuses when towing the vehicle so that the battery does not run down. There are commercial switches available for this purpose from the towbar manufacturers, however, I could not find any that would switch 3 fuse circuits - which is what I needed for my vehicle. Therefore, I am going to have to fabricate my own. Typically, these switches replace the fuse in the fuse panel with a connector, then run a cable to a remote fuse and switch, which allows you to effectively turn the fuse on or off with a switch. One difficulty in accomplishing this feat is to come up with a way to insert a connector into the fuse panel.
I have come up with a method of making a custom connector to replace the fuse that works quite well. First, make a cable set which has the same "tangs" as the ATM fuses. This may actually be more difficult than you may think, as I could only find one terminal connector that had both the same width and thickness of an ATM fuse connector. These terminals are made by Morris Products, and are item 11944 Male Disconnects, and are 0.11" wide by 0.032" thick. I could find plenty of connectors that were 0.11" wide, but they are typically only 0.020" thick, which will not work as well.
The first step is to create a pattern. I did this by pouring some Casting Plaster around a cable. You don't want to use Plaster of Paris here if you can help it as casting plaster is harder, so it will retain it's shape better as you handle it.
Next, shape the plaster to desired connector shape. You may need to test the shape a bit as some vehicle's fuse blocks are recessed, so you may need a certain shape for it to properly fit.
Create a mold by pouring Casting Silicone into a cup and around the pattern. The silicone will take several hours to dry, so make sure you follow the directions.
Finally, create the connector by inserting the terminated wires into the mold and pouring the connector body with Electronic-rated Potting Compound.
Video on making the Connectors.
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