Need HELP! fuse blowing

[bondo]

So Ive been driving my car for a while with out this problem but it just came back tonight after doing a pull out of a stop ight( i do it a lot). My main fuse which is now a 30amp fuse keeps blowing when I drive it for a little bit, then boom. then I put a new one in and same thing happens. If I'm just revving it it doesnt blow. And after it blows only when my headlights are on the charge light comes on. what could be the problem? Its a new alternator(festiva alternator). And a optima battery. thanks

[bravekozak]

Need more info. Model year. 88-89 had no headlamp relay, 90-93 had a headlamp relay. Headlights do not go through the fuse panel, only main fuse in engine compartment. Then through combination switch on the steering column. Take off the column covers and unplug the headlight connector (during the day of course), drive around and report back. I want to see if it's your alternator causing the problemo.

Also, look for visible bare wires touching metal in the headlight circuit.
Double check voltage to make sure your alternator is charging normally.

[bondo]

92 and Ill check on that!

[bondo]

So my set up is 3 mini fuse holders and all are holding 30amp fuses. the alternator fuse on is blowing. I just put a new one in and it seems to blow only after 2min of a consistent rev. what could cause this? the fuse holder and wire get hot too

[WmWatt]

What happens when you don't start the engine and turn on the headlights, and also try the turn signals?
If you unplug the headlights while driving does it still blow the fuse? (Nasty to have to blow a fuse on every test!)
How about if you just unplug one headlight? Or the other one?
Sounds like it only blows the fuse when the car is in gear?
Could it be road vibration shaking a loose connection and causing an intermittent short?
I'd look at the headlight wiring and connections under the hood for corrosion.
An easy thng to try is to spray the light switch on the steering column with WD-40 or contact cleaner.
Good luck.

[bondo]

found out that the wire was to small and getting really hot causeing the fuse to blow. got a 40amp fuse and bigger gauge wire

[Flyin4stroke]

Don't over power a bad connection it could cause a fire. That's why fuses that are the right size are important. You can't take out a 20 amp and replace it with a 40 amp. Because if anything goes wrong it won't blow.