Reliable Connections to the fuse blocks.

[Al Skierkiewicz]

To all,
The transition block and the 40 amp fuse block are both designed to take #2 guage wire. #6 finely stranded wire (super flex, etc.) allows the strands to ride up inside the threads of the clamp screw. On # 6 and #10 less than the full diameter of the wire can be adequately clamped. This is one solution to a more relaiable and less resistance connection...
For #6 guage terminating into the #2 block:
Start by cutting the wire at least 1/2" longer at the end that will be inserted into the larger block.
Strip 1" of insulation from wire.
Carefully fold back half the length of the exposed wire, forming the end with pliers, into a tight bundle.
Back out the clamp screw on the block and carefully insert the folded wire end into the block, making sure all individual conductors are inserted.
Tighten the clamp screw and test the connection by pulling on the wire.

For #10 guage terminating into the #2 block.
Start by cutting the wire 3/4" longer than needed.
Strip 1"-1.25" of insulation from the wire.
Tin the very end of the wire to hold conductors together. (just the very tip, no more than .125")
Fold two thirds of the exposed length back against the wire end, froming with pliers into a tight bundle.
Fold the tinned, one third back towards the end and form with pliers into a tight bundle.
Back out the clamp screw on the block and carefully insert the folded wire end into the block, making sure all individual conductors are inserted.
Tighten the clamp screw and test the connection by pulling on the wire.

Both of these methods allow the block to be filled by the conductors and produce a tight connection with fully engaged conductors for the wire guage used.

See pictures attached of our blocks.