Fuse Panel Cover

An enquiry to the registry made me realize that I never documented another small project from a long time ago.

My car was missing the fuse panel cover.  This is a metal piece that covers the fuses, relays and wiring on the panel.  I've seen two styles, one is a pressed cover with rounded corners and edges.  The other is simpler, consisting of a box made from .050 aluminum with folded edges and pop riveted together.  Both styles are black wrinkle paint on the outside.

Here are originals.

I used the folded example as the pattern for mine.  Pretty simple to make, a couple of cuts, three folds and two pop rivets and it's ready to wrinkle paint.  Here are the dimensions.  Clicking on the picture will open the TIF file that you can save or print.

1. Cut on the outside dimensions.
2. Make cuts A and B.
3. Fold the ears at 90°.  Note, these folds are slightly inside of the lower folds so the ears on the inside.
4. Fold the top at 90°.
5. Fold each side at 90°.
6. Drill a single hole in the right and left sides through the ears.
7. Fasten the sides and ears together with a small short pop rivet.
8. Drill holes for the hold down studs on your fuse panel.
9. Paint the outside with black wrinkle paint.
10. Install using the special knurled nuts (PF #239.80.348.0.2, same as on a GTE).  I put a small rubber washer under each nut.  That keeps the nuts from vibrating loose and you don't need to tighten them as much.

Note, this is for a 2HL model with the 16 fuse panel.