1G Battery Relocation (w/schematic) now blowing alt. fuse

[Ravenous]

I relocated my battery to the trunk back towards the end of the summer to make room for my catch cans and now I am blowing the alternator fuse (80 Amp) on a fairly regular basis. I got the idea for the relocation from this video on Youtube:

YouTube - GSX Battery Relocation

There was not a schematic posted so I followed the video and drew up my own:

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The 80Amp fuse is in an in-line fuse holder(POS, but the fuse is snug). I thought that the alternator might be getting wet and grounding the stud on the case so I covered the stud in rtv and it did not make a difference. The fuse usually blows when the headlights are on and when it is wet(it is always wet here so that may make no difference). It doesn't always blow just occasionally(approx 6 times in 400 miles). So here are my thoughts:

The AGU fuse and holder may be to fragile for the engine compartment of my car.

The alternator is pushing more amps because the ground is no longer in the engine bay??? (grasping on that one but it is my understanding it grounds through the case and since I'm grounded in the hatch it might be to much resistance)

I missed something in the schematic and the alternator may need to be connected to the fuse box? Maybe the alternator should be doing something other than just keeping the battery charged?

I don't really want to just throw money at it, so if anybody can offer some advice I'd really appreciate it.

-=Chris

 

[smprende10]

It sounds like youre having a short problem you can blow that fuse if the power wire gets grounded. May want to go back and recheck the cable going to the alternator and make sure its not grounding anywhere. Look of chaffing or any sort of connections the may have the chance to ground

 

[Ravenous]

That was my initial thought as well. I looked and didn't see anything and tugged on the wires while the motor was running to see if I could recreate the situation. Even turned the headlights on while I did it. It doesn't mean I didn't miss it, so when I am changing my oil drain tube I'll see if I can find a short while I'm under it.

 

[sniver]

Maybe you have a voltage sensing wire broke, making the alternator work full load, and some how, magically(dsm alts suck) its actually making more than 80 amps?


Bad battery makes the alt work to hard..

Try a different fuse assembly?


Also his setup appears to go alt>wiring>stock fuse>main distrubion, where the starter bolts to. Not the same as your diagram.

 

[Ravenous]

I ended up changing the AGU fuse out for an ANL type(bolt on=more secure connection) and changed out the 2 alternator wires for a single 1 gauge wire. I cut a piece of heater hose and soldered a 1 gauge ring terminal to the alternator end so I can bolt it on. The cut piece of heater hose goes over the stud on the alternator as a protective washer to make sure it doesn't shore out on the housing. I watched the video again and the only difference I can see is that he had the 4 fuse box wires(bolted in two places to the fuse box) contend with where as on a 1g there was an alternator wire and a power wire. That is from memory but I believe there was only the one stud to be concerned about on main fuse box so distribution wasn't necessary like on the 2g. I will take a more in depth look at that when I get a chance but as of right now it seems to be going solid. I am logging voltage so I can try to pinpoint exactly when and what causes it to blow.