Denali PowerHub2 - Cant hold it in any longer !

[Ablumny]

Looking to clean up your accessory wiring and thinking of a central power distribution box? I was and recently purchased a Denali PowerHub2, power distribution unit from Twisted Throttle Saw lots of positive reviews, some criticism but I liked that enclosed approach and the replaceable relay.

QUALITY:

• Upon inspection:Noticed the glue used to provide some sort of protection or strain relief for the wires in the thru holes of the PCB were doing nothing
• Gave a small yank on the main wires to inspect further and the entire PCB popped out of the plastic enclosure
• That gave me a nice view of the crappy cold solder points for all of the wires and a tiny bit of glue to hold the PCB to the box
• Both main wires had strands of unsoldered wires hanging out
• Then I notice the enormous gauge main wires to the relay and board continues on as 14 gauge wires from the relay to the boardIt appears the main wires are way over spec'd and they are stranded speaker wire material
• It appears the rest of the wires are under sized, especially if you start pulling anywhere near the max amps the relays can support (which is unlikely anyway)

I want the thing to work and I like the concept so I decide to fix and modify it myself and move on BUT I decide to send Twisted Throttle an email of my experience in hopes of helping to identify manufacturing and design issues. They were responsive, appreciative, offering to take it back if I wanted and no matter what I decided, plopped 4000 point in my account for the feedback ($40) Ok so that was nice....

INSTALLATION

Ok now its time to install it.

• with a reasonable amount of hot glue to re-secure the PCB, the board now sticks up enough that when fuses are installed, the cover isnt flush, I bet the cover wouldn't sit flush no matter what. To tight a design.
• its a nice idea to have the connection point enclosed but there is no way you'll ever route the main wires plus six pair of accessory wires thru the hole, make the bends and the connection points.
• The mini fuse blade holders are so tight that any attempt to remove them without care results in the PCB breaking away from the enclosure again They are way too tight

In summary the device works for now. The concept of a completely enclosure system with a replaceable relay is solid. ... Twisted Throttle is great but this thing is a +$100 piece of crap.

** If you've got one and its working well, do yourself a favor and turn the PCB over and reflow the silver solder (which will need a serious iron) at the wire points. I also cleaned off and reflowed new hot glue over each wire on the top side. I will figure out way to extend the depth f the body to deal with the fuses that are too high now.

** If you are researching, consider the FuzeBlocks system I suspect!

Hope this helps someone

Andrew

 

[Nanahanman]

Great write up!

You are right that it is too small. Even a 1/2" extra on each side would have made a difference.

I suspect the people that build this crap don't ever have to install it.

 

[Kaelaria]

Thanks for the great info!

 

[Pterodactyl]

Probably saved several people some grief.

 

[dcarver]

Those guys solder like one of my former employees....

 

[Ablumny]

I have a lab full of electrical engineers in my office. They tore the thing apart (and me for buying it) but glad I had them to point out the possible failure points.

 

[900gc]

Ditto on the great info on the 'quality' of this product. I work in aerospace QC and this kind of stuff never fails to gripe me. Incidentally, the Easternbeaver PC-8 fuse panel, which I use, is high quality (as is all of Jim's stuff) and can now be had for only $55!

https://www.easternbeaver.com/Main/Wiring_Kits/Fuseboxes/PC-8/pc-8.html#pc8only

 

[Mudslide Miller]

I'm surprised you decided to even think about fixing it yourself. I would have sent it back in a heartbeat and pursued another brand. Twistied Throttle should be purging every single one of these from their inventory and discontinue selling them until followup QC can clear a new lot number of them. I also work in aerospace wiring and repair and I would lose my job immediately if I put out soldering like you described.