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Hello All,

This post is to share a modification I have done, maybe helping somebody else who is frustrated with fuse contact problems.

The car: 1991 240.

I used these: http://www.digikey.com/product-detail/en/3557/3557K-ND/2092485
and soldered them to the original fuse holder.

I tried a little butane torch first, doesn't work, too much heat for the plastic. What worked well was a big old 100w soldering iron for stained glass work. (see pic)

I used a small bar of aluminum as a jig so simulate the fuse during soldering. Using a fuse didn't work because the plastic would melt or the spade would get soldered. The bit of Al was just tin-snipped from some sheet. SS would work, or rusty steel, anything that resists soldering.

I cleaned the terminals up with a mini wire brush on a dremel tool. I also used some pretty aggressive water clean up acid flux, and cleaned the whole thing in hot water after.




--Karl