Author Topic: How to make a Fusible Link  (Read 28537 times)

Offline VileZambonie

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How to make a Fusible Link
« on: March 05, 2008, 02:43:30 PM »
Repairing an open fusible link is pretty straight forward and easy but first always isolate the root cause of the problem. Simply replacing a burned fusible link without diagnosing why the link opened is asking for another melt down. Replacing a fusible link with a larger gauge link is also NOT acceptable. If additional components are added to a circuit causing an overload then a seperate protected circuit should be made. Bypassing fusible links with no circuit protection is foolish and will result in a melted wiring harness or fire.

To replace a fusible link you will need a few basic items:

Proper gauge and length fusible link wire -(Typically a fusible link is two wire gauges smaller than the wire it is protecting)
Terminal assortment
Heat Shrink
60/40 Rosin Core Solder (I prefer 1/16" diameter)
Wire strippers
35 watt or higher soldering iron

First select the appropriate terminal and fusible link wire gauge needed. The link should be about the same length as the original. Strip the ends of the link

Connections should interlock and not be twisted around. Apply soldering flux to the joint

Heat the joint with the soldering iron and feed the solder into the work. Make sure the solder flows and penetrates all the way through the strands.

Solder the terminal on to the opposing end and wipe clean the soldered joints

Slide the appropriate diameter shrink tubing over the connections and shrink them using a heat gun or blow dryer

That's it! If you want to get really fancy you can purchase factory style connectors and links but for functionality and cost effectiveness this works well.
« Last Edit: February 07, 2019, 07:49:21 PM by VileZambonie »
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