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FYI--a set screw type ferrule might be secure, but is NOT necessarily equivalent to a properly crimped ferrule in terms of electrical conductivity.
The reason is simple ... a proper crimp physically compresses all of the individual soft copper wires into full contact with each and every wire next to it, and also into the confines of the ferrule, until the ferrule body effectively becomes the entire contact surface.
With a set screw type wire ferrule, the set screw mostly penetrates between the wires (actually pushing some of them apart even while still pressing some of them together, but ONLY at the screw contact point.
In short, while the set screw DOES effectively secure the wire to the ferrule, it does NOT have the conductivity advantages of a true crimp wire ferrule.
Please know that I am NOT saying that using set screw ferrules is the source of your ground problem, or even that your set screw ferrules are not making a good connection...
That said, you DO indicate that the fuse holder overheating has followed your install through different iterations and fuse holder brands. And you also say that the the set screw ferrules are original to your install. And it also sounds like you have more then a couple of those screw ferrules being used as a ground.
Since overheating fuse holders ARE a sign of potentially poor ground connections SOMEWHERE...I suggest actually finally checking those set screw ferrules for positive contact INSIDE the ferrule and NOT just by physically tugging on it.
Alternatively, and as long as you have at least 1" of slack on each end of each wire, you could simply cut the screw ferrule off, strip the wire back the additional inch, and replace it with a proper crimp ferrule.
Of course you also need a proper and clean frame grounding point as well.
just my .02
The reason is simple ... a proper crimp physically compresses all of the individual soft copper wires into full contact with each and every wire next to it, and also into the confines of the ferrule, until the ferrule body effectively becomes the entire contact surface.
With a set screw type wire ferrule, the set screw mostly penetrates between the wires (actually pushing some of them apart even while still pressing some of them together, but ONLY at the screw contact point.
In short, while the set screw DOES effectively secure the wire to the ferrule, it does NOT have the conductivity advantages of a true crimp wire ferrule.
Please know that I am NOT saying that using set screw ferrules is the source of your ground problem, or even that your set screw ferrules are not making a good connection...
That said, you DO indicate that the fuse holder overheating has followed your install through different iterations and fuse holder brands. And you also say that the the set screw ferrules are original to your install. And it also sounds like you have more then a couple of those screw ferrules being used as a ground.
Since overheating fuse holders ARE a sign of potentially poor ground connections SOMEWHERE...I suggest actually finally checking those set screw ferrules for positive contact INSIDE the ferrule and NOT just by physically tugging on it.
Alternatively, and as long as you have at least 1" of slack on each end of each wire, you could simply cut the screw ferrule off, strip the wire back the additional inch, and replace it with a proper crimp ferrule.
Of course you also need a proper and clean frame grounding point as well.
just my .02
