Holy Grail Labs - Blade Fuse Upgrade Kits

[Ju@n]

The fuse that is for the Hazard switch, obc, etc. I made a new ground on the bracket that holds the coolant reservoir but I made the ground on the flat surface near the threaded hole.

Fuse 5? Central locking blowing 7.5A fuses in F5 is a somewhat common issue

I'd add that as a warning in the initial post, so people stop blowing fuses unnecessarily
Or just install a 10A fuse when you ship it haha

[PhilC]

[/quote]
Yeah 02s are on the list, can you reach out to the support email and send a picture of your fuse box?
[/quote]
I don’t seem to be able locate the e-Mail address anywhere? I’m sure I’m missing it somewhere but could you point me in the right direction please.
Thank you

[Galahad]

I don’t seem to be able locate the e-Mail address anywhere? I’m sure I’m missing it somewhere but could you point me in the right direction please.
Thank you

sorry, it's support at holy grail labs dot com - trying to keep the amount of spam crap to a minimum

[MisterFixit]

I applaud your efforts on the E28 and 2002 fuse boxes, Galahad! I drove a '72 for decades... and loved it to death!

'02 on the list- question:
For the 02 fuse box, I know there were two- 6 fuses and 12 fuses. Has PhilC indicated which one he is sending pics of???
I can send pictures of the 12 fuse version, I have a full wire harness from a later car. I am glad to send you a picture if that would be helpful.

Andy

[Galahad]

I applaud your efforts on the E28 and 2002 fuse boxes, Galahad! I drove a '72 for decades... and loved it to death!

'02 on the list- question:
For the 02 fuse box, I know there were two- 6 fuses and 12 fuses. Has PhilC indicated which one he is sending pics of???
I can send pictures of the 12 fuse version, I have a full wire harness from a later car. I am glad to send you a picture if that would be helpful.

Andy

He sent pics of a 12 fuse box - I've got a pretty good idea how to move forward, just need to figure out how many different 12 fuse boxes were used and what the changes are.

[Galahad]

Unfortunately I'm not at Vintage, but we're offering 10% off our Blade Fuse kits for the event - use the code Vintage2023 at checkout. You don't even have to attend the event to get the deal!

[Galahad]

Just a quick update - I found a manufacturing partner for the fuse boards and have confirmed they meet our quality standards! I'm waiting on the first batch of new units to arrive; shipments for orders placed now will be delayed about a month.

[torin.kw]

E28 Retrofit Kits are available for purchase!

Buy One Here!

Also available for E21

Upgrade your flakey, melty, and unreliable E12, E23, E24, or E28 fuse box.

Address one of the biggest causes of electrical problems in your classic BMW—the ancient and unreliable torpedo fuses. Our kit upgrades your E12, E23, E24, or E28 to modern, reliable blade-style fuses.

• Lower total resistance and won't lose spring pressure over time
• Prevents melty
• LEDs show green for any circuit with power; red if the fuse is missing or blown
• LEDs can be disabled via a switch
• Includes sockets for four spare fuses
• Fits under the stock fuse box cover
• Includes a full set of blade style fuses

IMPORTANT: This kit requires the modification of the fuse box by removing the bullet (torpedo) fuse holders. Once the torpedo fuse holders are removed the new circuit board drops into the existing slots through the plastic.

The "E28 Blade Fuse Box Upgrade Kit" is compatible with

• All BMW E12 models
• All BMW E23 models built before September 1982
• All BMW E24 models built before September 1982
• All BMW E28 models

E28 Blade Fuse Box Upgrade Kit Installation Manual

E28 Blade Fuse Retrofit Kit Install Walkthrough Video

Product Photos:





----------Original post below----------

Hi everybody,
I've been working on a blade fuse retrofit kit for e28 fuse boxes for a number of months now and it's high time I made my own thread about it. I'm very close to a final version and will be posting updates here as progress is made.
I'd like to thank @cek for offering up his cars as guinea pigs - his input has been invaluable for improving the final product.
Quick specs:
Compatible with standard / mini / low-profile blade fuses (no longer applies from 5/28/23 onwards, I had to make a change to support manufacturing efforts)
Works with both Euro and US cars
Lower total resistance and won't lose spring pressure over time
Indicator LEDs to identify blown fuses
Does require modifying the fuse box by removing the bullet fuse holders, but drops into the existing slots through the plastic
Fits under the stock fuse box cover

Here's a photo of the current prototype:


See the installation here.

Let me know if you have any questions.
-Galahad

Hi, i recently installed the blade fuse kit into my 535is and it’s working great with only a couple issues, including the rpm gauge being unresponsive, the gauge light and power locks not working. I feel I must have switched some connectors around on accident when re plugging them into the bottom of the fusebox chassis but can’t seem to find which ones i would have switched, and was wondering if there is some method to finding which connectors may be the issue?

[Galahad]

Hi, i recently installed the blade fuse kit into my 535is and it’s working great with only a couple issues, including the rpm gauge being unresponsive, the gauge light and power locks not working. I feel I must have switched some connectors around on accident when re plugging them into the bottom of the fusebox chassis but can’t seem to find which ones i would have switched, and was wondering if there is some method to finding which connectors may be the issue?

Tach and power locks are both on fuse 5, gauge lights are on fuse 9 best I can tell - do you have the ETM for your car?

[torin.kw]

Thank you, I don’t have ETM but i’ve been looking for it for a while now.

[Galahad]

Thank you, I don’t have ETM but i’ve been looking for it for a while now.

Download the one for your car here

[Galahad]

Just a quick update - I found a manufacturing partner for the fuse boards and have confirmed they meet our quality standards! I'm waiting on the first batch of new units to arrive; shipments for orders placed now will be delayed about a month.

We're back in stock, and I've shipped out the back orders

[Zeta]

Received mine a few days ago! Looking forward to getting it installed.

[Bonsaibacker]

Just finished installing and I love the results. Follow the instructions for installing and watch the video. It is a seemingly difficult operation but the video is accurate enough to eliminate challenges.

Took 3.5 hours with the assistance of a spare fuse box and a system using small colored zip ties to bundle wires of a row together. Took a few zipties for some rows but starting with the first row as red, every successive row followed ROYGBV.

I am looking to pass the fuse box and some spare zipties on to anyone doing the upgrade- $25 plus shipping.

[Galahad]

Just finished installing and I love the results. Follow the instructions for installing and watch the video. It is a seemingly difficult operation but the video is accurate enough to eliminate challenges.

Took 3.5 hours with the assistance of a spare fuse box and a system using small colored zip ties to bundle wires of a row together. Took a few zipties for some rows but starting with the first row as red, every successive row followed ROYGBV.

I am looking to pass the fuse box and some spare zipties on to anyone doing the upgrade- $25 plus shipping.

Happy to hear install went well!
The zip tie idea is genius, I've been trying to come up with something like that.

[Zeta]

Took 3.5 hours with the assistance of a spare fuse box and a system using small colored zip ties to bundle wires of a row together. Took a few zipties for some rows but starting with the first row as red, every successive row followed ROYGBV.

Great idea! I have some spare zip ties like that from when I replaced my Tacoma’s engine a couple years ago (marking all the electrical and vacuum connections), so I’m definitely gonna do that too.

[Kerrvillian]

I've got one of these kits in my '85 524TD and it's been such an upgrade over the crappy torpedo fuses. I ordered mine Memorial Day weekend, so I guess I got one of the last ones before they went out of stock recently.

I did my wire removal in sections and took detailed photos on my phone as I did so. Several of the old terminals were very loose or had melted wires from crap connections for years and years. If you're installing one of these kits, replace any suspect terminal! If you put a burnt/loose terminal back on, you'll have a hot connection despite the improved ATC fuses.

I also have H4 lights fitted to my car to replace the original sealed beams and had to upsize Fuse 7 and 8 to 10A. Otherwise, the 7.5A high beam fuse would pop every time you flashed or switched to high beam. Interestingly, the 8A fuses in the torpedo box didn't do this, so it must have been right on the threshold of what they could handle.

One minor gripe: Include some printed instructions! My phone is usually not with me when I work on my cars and printing a couple pages of instructions with some diagrams or photos wouldn't cost but a few cents. Just a suggestion!

[Galahad]

I've got one of these kits in my '85 524TD and it's been such an upgrade over the crappy torpedo fuses. I ordered mine Memorial Day weekend, so I guess I got one of the last ones before they went out of stock recently.

I did my wire removal in sections and took detailed photos on my phone as I did so. Several of the old terminals were very loose or had melted wires from crap connections for years and years. If you're installing one of these kits, replace any suspect terminal! If you put a burnt/loose terminal back on, you'll have a hot connection despite the improved ATC fuses.

I also have H4 lights fitted to my car to replace the original sealed beams and had to upsize Fuse 7 and 8 to 10A. Otherwise, the 7.5A high beam fuse would pop every time you flashed or switched to high beam. Interestingly, the 8A fuses in the torpedo box didn't do this, so it must have been right on the threshold of what they could handle.

One minor gripe: Include some printed instructions! My phone is usually not with me when I work on my cars and printing a couple pages of instructions with some diagrams or photos wouldn't cost but a few cents. Just a suggestion!

You were one of the last ones before the current batch, we are back in stock at the moment.

I agree on replacing bad terminals, they cause the same issue as loose connections to the torpedo fuses.

The torpedo fuses are rated as "indefinite carrying capacity" while the ATO fuses are rated as "will blow" - the 0.5A rating difference isn't the issue, the change in meaning is. There's some good discussion about it in the fuse #5 thread.

Including printed instructions is a good suggestion, I'll look into it.

[325racer]

Just ordered one last weekend, what is delivery schedule looking like?

Hoping this will reduce some of the electrical gremlins I have in my old 528e

[Galahad]

Just ordered one last weekend, what is delivery schedule looking like?

Hoping this will reduce some of the electrical gremlins I have in my old 528e

Thanks for the order, I just boxed it up - I was on vacation this week. Hope it'll fix your problems too!

[325racer]

Thanks,

Saw the shipping notification. One issue I know it will fix is my lights and antenna. Determined both were due to flaking fuse connections.

Might fix HVAC fan, but I think that's a seized motor I need to replace or unstuck.

[325racer]

Got mine installed today. Car starts up, radio works, roof, windows, and most stuff, but I must have mucked something up with headlights and turn signals as those aren't working. Will have to look things over on Sunday.

[325racer]

I would if I knew what mine did! I think it used to power an old car phone. Wires run into the back of the glove box, with nothing attached.

On that note, I just removed the old external cell phone antenna.

Open question: Who would want a Mini-Box Upgrade Kit?
No LEDs, just two blade fuse holders. Pic of the prototype:
Mini box by Holy Grail Labs, on Flickr

[325racer]

I've run into an impasse and am kinda stumped.

Got everything installed Friday and found the lights/turn signals didn't work, but most else seemed to work. I got back to troubleshooting today.

I found that I had a few wires moved around in the headlight/turn signal areas, but not much, mostly just leaving an open spade or not. Mine is slightly different than the Flikr page.

Mine

http://koganmb.quickconnect.to/mo/sharing/2Ld1rVKHt

Holy Grail

https://www.flickr.com/photos/ckindel/5 ... 301732523/

Overall they are very close.

Here's what's happening. Car starts fine, wiper work, radio works AC and fans work (well fan is dead but trying to work) Brake lights work.

When I turn on headlights, the left turn indicator illuminates, Check light comes on and Low Beam, washer fluid and coolant indicators come on, but lights do not.

The fuse block lights up through.

http://koganmb.quickconnect.to/mo/sharing/HAsriI1kB

When the hazards are turned on they did work once, but generally turn signals don't work, but the fuse block flashes.

http://koganmb.quickconnect.to/mo/sharing/WVuPcKSB4

Now, when I turn the car off, the fuse block LEDs stay on until I disconnect the battery.

http://koganmb.quickconnect.to/mo/sharing/pCXmzn5TG

[Galahad]

I've run into an impasse and am kinda stumped.

...

Wow that sure is something. I can look into the ETMs more in the next day or so.
I'd try pulling every fuse (or at least the ones related to the issues), then put each one back by itself to see what gets power.

[325racer]

Good idea, will probably try that later in the week or next weekend. If you see anything that makes sense, please let me know.

[Galahad]

Good idea, will probably try that later in the week or next weekend. If you see anything that makes sense, please let me know.

I looked at the ETMs and the schaltplane and I am stumped. Get any testing done? It could also be helpful to pull the lighting relays and see what changes

[Galahad]

Happy new year!

I'm looking for people to test two prototypes, both for E10 / 02 cars.
one is fuse box part # 61131352373 (12 fuse 03/71 to 08/73, has sideways blades)
the other is part # 61138460100 (6 fuse 03/66 to 04/72)

Testers would need to get me info within a month and will receive a free production unit once I have made any necessary changes.

Reach out to the HGL support email (support@[website]) if you're interested!

[pdor123]

Hi, I have a US m5 with the euro headlights converted by a prior owner. After installing the HG fuse panel I incorrectly bridged fuses 7 & 8 so fuse 8 (left high beam) blew.

Another glitch that could be related: I depinned connector 85 from the high beam relay but destroyed it. After repairing it, I replaced fuse 8 and removed the bridge at fuses 7 & 8 and inserted 15 amp fuse in fuse 7 per troubleshooting FAQ.

When low beams are on, both sides work. If high beams are on, only the right high and low beams work, and neither the left high and low beams work.

The center red lens of the tail lights are illuminated when the battery is connected even without the key in the ignition. Removing fuse 9 temporarily resolves the issue. The lights were modified previously to add an additional bulb in the extra space. I did not notice this issue until after troubleshooting the headlights.

I noticed a few differences in the photos in the HG flicker account and the ones I took. Ex: The gray/white wire is on an adjacent tab of the same colored cardboard index. I initially put the connectors back according to my photos and then according to the flicker account, then in various combinations of both. I still have issues with the headlights and the tail lights. Please help. Thanks in advance. Patrick

[MisterFixit]

Hi, I have a US m5 with the euro headlights converted by a prior owner. ... Please help. Thanks in advance. Patrick

Patrick, this sounds like another thread is in order, at least a private consult. I have done several headlight conversions for Euro operation (2002 and E28 and E30) that lights high and low filaments simultaneously... safely.

I have also been upgrading rear lighting for decades. I believe the HGL fusebox upgrade shouldn't be the source of any issues there... and can help you troubleshoot the weirdities in back as well as add more lighting safely for higher output, greater reliability, and a larger visual profile. Shoot me a PM and we'll talk.

I am curious about your statement about 'destroying' the relay 85 pins...

Andy

[Galahad]

Hi Patrick, sorry to hear about your issue. Email would probably be easier, I suspect you've swapped a couple wires around.
-Galahad

[MisterFixit]

Hi Patrick, sorry to hear about your issue. Email would probably be easier, I suspect you've swapped a couple wires around.
-Galahad

+1

[pdor123]

I am curious about your statement about 'destroying' the relay 85 pins...

Andy

I inadvertantly destroyed the connector that relay pin 85 plugs into.

[pdor123]

Hi Patrick, sorry to hear about your issue. Email would probably be easier, I suspect you've swapped a couple wires around.
-Galahad

Please advise how to contact you via email. I'm new here and only see a link to your HGL site. Thanks, Patrick

[Galahad]

Hi Patrick, sorry to hear about your issue. Email would probably be easier, I suspect you've swapped a couple wires around.
-Galahad

Please advise how to contact you via email. I'm new here and only see a link to your HGL site. Thanks, Patrick

It's support(at)[HGL site]

[MisterFixit]

I inadvertently destroyed the connector that relay pin 85 plugs into.

Oh, I see. You say you repaired it, but if you need more of the locking connector (female terminals), I have bags of them. They are new Hella parts.

Let me know if you want anything regarding rear light repairs, upgrades, etc.

[Galahad]

Got Patrick's car working; US cars that were converted to euro front lighting at the headlight plugs need the bridge fuse since the fuse box wiring hasn't changed.
That edge case hadn't been addressed anywhere, I updated the FAQ to clarify.

[pdor123]

Thanks for the exceptional support.

[Galahad]

Hi everybody!

Holy Grail Labs is excited to announce a new product line of blade-style fuse boxes for the BMW 02 and E3 series cars!

The new products are full fuse box replacements, including a new frame, gasket, OEM cover, and fuses. These fuse boxes include Holy Grail Labs' time-tested LED indicator circuitry. Installation is as simple as removing the old fuse box and plugging in the new unit.

We are providing both 12-fuse variants, covering 3/71-8/73 cars and 8/73-7/77 cars. The latter box also fits BMW E3 models built 9/73-2/77.

A kit to replace the 6-fuse variant used in 3/66-4/72 cars has been designed, if you are interested in testing this contact us at support (at) holygraillabs (dot) com.

MSRP is 319 USD, available now! Visit our store page to place your order today.

I've included photos of a prototype below, so you can expect minor differences in the production version.

[Shawn D.]

Holy Grail Labs is excited to announce a new product line of blade-style fuse boxes for the BMW 02 and E3 series cars!

Sweet! Y'all are really doing some great work supporting our vehicles!

[Galahad]

Holy Grail Labs is excited to announce a new product line of blade-style fuse boxes for the BMW 02 and E3 series cars!

Sweet! Y'all are really doing some great work supporting our vehicles!

Thanks! got a couple more coming down the pipe too

[Galahad]

Hi everybody!
All the new units - E3, E9, and both 12 fuse 2002 variants - are in stock! We're happy to have been able to reduce the price to 319 USD for the new models and are looking forward to getting these into peoples hands.
As always reach out if you have any questions.
2002 Fuse Box
E9 Fuse Box
E3 Fuse Box

[jacobthegoat]

Quick question -

Just did the retrofit blade fuse project yesterday. Everything works properly except fuse #10

When I use my left blinker, the front bumper marker doesn’t illuminate, and it throws a check light on my check panel for rear license plate lights and rear lights, although they function just fine. Only the front turn signal marker doesn’t operate. I checked the bulb and also the wiring. Bulb is good. Wiring I’ve checked twice, everything is back where it was originally.

Also the LED on fuse 10 blinks on and off with the rhythm of the turn signal

[Galahad]

Quick question -

Just did the retrofit blade fuse project yesterday. Everything works properly except fuse #10

When I use my left blinker, the front bumper marker doesn’t illuminate, and it throws a check light on my check panel for rear license plate lights and rear lights, although they function just fine. Only the front turn signal marker doesn’t operate. I checked the bulb and also the wiring. Bulb is good. Wiring I’ve checked twice, everything is back where it was originally.

Also the LED on fuse 10 blinks on and off with the rhythm of the turn signal

Fuse 11 is for the blinkers, not fuse 10 (various marker lights). Something got plugged in wrong, having the LED blink on and off is a new one. Can you email us (or post here) some pictures of the wiring inside your fuse box? I'm looking at the ETM and it's not immediately obvious what could cause that.

[Galahad]

Hi everybody!

At long last we have mini boxes in stock and available on the website!



Price is 28 USD by itself, 21 if purchased with an E28 blade fuse upgrade kit. Kit includes a new mini box, a new bracket, fuses, and crimp connectors.

Available Here

[1st 5er]

Ordered.

[jacobthegoat]

Quick question -

Just did the retrofit blade fuse project yesterday. Everything works properly except fuse #10

When I use my left blinker, the front bumper marker doesn’t illuminate, and it throws a check light on my check panel for rear license plate lights and rear lights, although they function just fine. Only the front turn signal marker doesn’t operate. I checked the bulb and also the wiring. Bulb is good. Wiring I’ve checked twice, everything is back where it was originally.

Also the LED on fuse 10 blinks on and off with the rhythm of the turn signal

Fuse 11 is for the blinkers, not fuse 10 (various marker lights). Something got plugged in wrong, having the LED blink on and off is a new one. Can you email us (or post here) some pictures of the wiring inside your fuse box? I'm looking at the ETM and it's not immediately obvious what could cause that.

Turns out everything was wired correctly, the bulbs tested good, but after replacing the turn signal bulbs with new ones, everything works properly.

Dang I was just a few weeks late to order the spare fuse box! Price is good for those, I spent $50 on a replacement bullet style aux fuse box just a few weeks ago. Nice work.

[Galahad]

Turns out everything was wired correctly, the bulbs tested good, but after replacing the turn signal bulbs with new ones, everything works properly.

Dang I was just a few weeks late to order the spare fuse box! Price is good for those, I spent $50 on a replacement bullet style aux fuse box just a few weeks ago. Nice work.

Weird solution but glad it's resolved!
Thanks for the positive comments

[Galahad]

We have color cards for E28s now! They are a huge help when installing fuse box kits, I was able to do 90% of a box without needing to look at photos. Euro on one side, US on the other. Made out of temperature resistant materials, and colors were picked to match how the wire colors usually fade.



Currently these are for E28s only, we're looking into the other models that the E28 kit works with but there's a significant number of variations.

16 USD, available here if you're looking for some extra help on an upcoming kit install.