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Need help determining cause of a melted fuse holder


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Here is my current setup, I am new here so if I miss anything please let me know.

The vehicle is a 03 Ford Explorer Sport(not sport trac)

Head unit is a Kenwood KDC-X896

Front speakers are Focal 165 A1SG components

Rear speakers are Focal 1656 CA1SG coaxials

4-Channel Amp is a JL Slash 300/4v2

I used a Stinger 4 AWG wiring kit (SK6241) and their mid level RCA's to connect the amp, making sure to put an inline fuse about 8 inches away from the battery. The system has run great for the past year and a half until yesterday. While driving on the highway with the volume set to 27(75%) the sound cut out randomly. It came back on about 3 seconds later and played for a minute and cut off again, this time taking around 10 seconds before turning back on. Eventually it got to where I would only get a flicker of audio and it would be off most of the time. I checked out the amp and saw the green power LED would come on an off every 3 seconds. When metered, I saw it start at 14v with the green LED on, then drop to 8v in a matter of seconds with the LED turning off under 10v. The voltage would then raise back up to 13.5v or so and repeat. When I checked the fuse under the hood I found this.

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The melted end had the wire coming in from the battery

I also noticed there are circle marks on the sides of the fuse holder if that means anything

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What I can't figure out is what caused this and why the fuse didn't pop. If anyone here has any ideas fire away

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Its a bad.connection. causes resistance. Fuse is probably melted solid because of it

THERE IS NO BUILD LOG!

1998 Chevy Silverado ext cab

Alpine CDA-9887

4 Team Fi 15s

2 Ampere Audio TFE 8.0

2 Ampere Audio 150.4

3 Digital Designs CS6.5 component sets

Dual Mechman 370XP Elite alternators inbound!

8 XS Power d3400

6 XS power d680

Second Skin

Stinger

Tsunami Wiring

Sky High

A Real Voltmeter not a piece of shit stinger.

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Faulty fuse probably along with it being to big for 4 gauage. Bad connection also.

http://www.stevemeadedesigns.com/board/garage/vehicle/2438-jeep-commander/


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Its a bad.connection. causes resistance. Fuse is probably melted solid because of it

The connection at the car's battery and B+ terminal of the amp are both solid. The ground is less than 14" and is also solid so where is bad connection at? The fuse and its holder are definitely fried, but buying a new one isn't what I'm afraid of. I trying to stop it from happening again and causing a fire or something. Did a connection come loose or was it just a defective fuse?

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The connection to the fuse holder. You know the spot that melted into a pile. It has nothing to do with anything but the connections in the fuse holder

THERE IS NO BUILD LOG!

1998 Chevy Silverado ext cab

Alpine CDA-9887

4 Team Fi 15s

2 Ampere Audio TFE 8.0

2 Ampere Audio 150.4

3 Digital Designs CS6.5 component sets

Dual Mechman 370XP Elite alternators inbound!

8 XS Power d3400

6 XS power d680

Second Skin

Stinger

Tsunami Wiring

Sky High

A Real Voltmeter not a piece of shit stinger.

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May not have been fine.

May have been fine ans after all that time something cracked or worked loose etc. Its really tough to tell. Im not a fan of those fuse holders in the slightest ive seen that happen to a ton of them. Close second are the junk knu fuse holders.

THERE IS NO BUILD LOG!

1998 Chevy Silverado ext cab

Alpine CDA-9887

4 Team Fi 15s

2 Ampere Audio TFE 8.0

2 Ampere Audio 150.4

3 Digital Designs CS6.5 component sets

Dual Mechman 370XP Elite alternators inbound!

8 XS Power d3400

6 XS power d680

Second Skin

Stinger

Tsunami Wiring

Sky High

A Real Voltmeter not a piece of shit stinger.

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Heat,.. from amperage going high, from a not good connection.

Or the HOLDER in question was not able to handle said amperage, (not voltage)

That seems to ME why BOTH ends are goooooy. Not one, or the other.

I didnt read, but what size fuse did you have in there? Seems the fuse for the wire gauge, was to high. Or the wire was asked to much, then fuse was laid in.

Just me.

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