Design and Construction of Battery Fuses
Each pack in the New Beetle will be fused with large 400V 400A fuses. Unfortunately the fuse holders for these batteries cost $60 each! So custom built fuse holders were manufactured.
Here is how to construct large fuse holders:
- 3/4" of phenolic was used as the base. The base was drilled to accommodate stainless steel bolts. A 1" length of stainless rod (1" diameter) is drilled to provide an offset for the fuse.
- The stainless steel bolts are set into the base and epoxied over to provide for electrical insulation:
- Finally the fuse can be simply bolted on to the holder. The cables use the same bolt as the fuse.
- A close up of the rear fuses in their little home.