Large Fuse Holder / Cradle for EV

thingiverse

I needed to securely install the four massive 600 amp, 500 volt fuses for our powerful ~1000 HP land speed vehicle, the Green Envy. To save space, I decided to connect one end of each fuse to the GigaVac contactors, but this left the other end suspended in mid-air. I designed and printed a support system specifically for that loose end. The holder features two screw holes to mount it securely to the same plate as the contactor. I fastened the fuse to the support using a tie wrap that passes through a curved hole in the holder. (I created a curved hole because it's a breeze to do with 3D printing.) The support includes a slot at the top, precisely the width of the flats on a 3/8 inch bolt that secures the wire terminal to the fuse. This makes tightening the bolt a hassle-free process. After I test fit the black support in the photo, I produced one made from blue filament. The black contains carbon black as a pigment, which might make the plastic conductive. Out of an abundance of caution, I printed the ones I plan to use with blue filament instead.