[svxcess]

RING TERMINAL:

You will have to file down the outside of the 4 gauge ring terminal that attaches to the alternator so that it is smaller in diameter and fits completely down inside the black plastic collar on the power terminal and tightens securely to the post and bottom. Don't let it sit on top of the collar. It should fit in there loosely to allow for expansion when hot.

Use a file or a Dremel with a grinding wheel

A lock washer and nut will work. Just tighten very securely, not overtighten. Excessive Force will break the alternator charging post. Use a small 1/4" drive socket to avoid this.

The cable portion of the ring terminal will sit into the slot in the collar. This will prevent the cable from rotating when tightening


The MEGAFUSE BRACKET

I should have done a writeup with photos of what I did to address this. Basically it is attached to an aluminum plate that is folded over and just hangs on the edge of the fuse box. See photo 3.


Here are some photos. Look closely and you will notice in the photos that the fuse holder of mounted to some sort of metal plate (using pop-rivets)















I cut a thin piece of aluminum plate as wide as the widest part of the fuse holder. I then took off the fuse box cover and measured the distance from the top of may battery to the top edge of the fuse box.

Looking inside the fusebox there is a thin gap at the front of the box. I measured how deep this gap was. I transferred these measurements to the aluminum plate. The plate is bent over 180° so that it just slides over the edge of the fusebox and hangs snugly. Snap the fuse box cover back on and make a line on the plate where the bottom of the cover is..

Remove the plate and mark the position of the fuse holder (with the cover on) Make sure it does nor rise above the line you marked on the bracket. Mark the 2 holes for the mounting points and drill.

I used pop-rivets to mount the holder to the bracket. I inserted the rivets from the REAR of the bracket (so that the head was flush and did not interfere with anything.

Do the test-fitting of the bracket to make sure everything is fine. Inside the gap in the front of the fusebox there is a thin vertical rib of plastic that will keep the bracket from sliding down completely. Just cut a small notch on the bracket to slide over this. This will also act as a key and keep the bracket from sliding side-to-side when the fuse box cover is attached.


This is a secure fit. The fusebox cover clips on and prevents the bracket from moving. The bottom of my fuse holder just rests on the top of my Optima battery.


This is the general instructions for the procedure. Hope it helps. I may go out and take more detailed photos, but don't think it is necessary