I used to compete car audio.. (10 years ago before it became annoying – and when I was much younger). In the process I’ve rattled and rubbed my way to 100’s of faulty power wires.
20 Amps is a huge fuse to be blowing on trailer lights. Short answer is that you have a positive wire occasionally touching ground. It would be pretty damn odd to have a loose ground blow a fuse…. I wouldn’t start diagnozing the problem there. Check over all of your positive wires on the trailer for insulation rubbed off/cracked in-line to the lights. Also, if you have original Shorelandr’ lights check the plug-in backs for built up debris. If all looks good, pop the lenses off your lights and look for an internal light problem where a hot wire it touching ground.
You should be able to test all of this with a Fluke (or similar voltage meter) without blowing fuses. Set it to DC. Place one end in your harness on the hot. Run the other end (you might need to use sacrificial wire) to the hot on the light. Make sure these two are connected WELL. You will see the meter at 0.0 Next lightly pull and/or hold the wires a bit at different angles, pausing a bit at each one. Assuming your Fluke connections are WELL done, it should stay at 0.0 When you will see the voltage number float from 0.0 (2.6 to -1.4 to 0.6 to etc…) you have found your bad wire.
A few other notes, I would suggest placing gromits on places where wire enters the inside of your trailer and flex-loom everywhere else. This will protect your wires while preventing corosion and insulation breakdown.
One more note on soldering.. if you don’t have a soldering iron or don’t have time to solder a small trick of the trade:
1. Don’t use butt connectors.
2. Get the right sized crimp caps.
3. Connect your wire(s) using the crimp caps.
4. Grab your wires below the crimped connection.
5. Zip-tie the wires together 2 inches below the crimped caps.
6. Snip excess ziptie.
7. Place shrinkwrap over cap and wires to zip-tie.
8. Heat and shrink
9. You’re done!
This has a few advantages.. easy off and on with little wire loss, it’s fast and not dangerous , still can use tape or shrink wrap, and best of all when you pull on the wires (one in each hand for example) you put ZERO stress on the connection. All of the stress is located at the zip-tie. This creates a stronger and longer lasting connection than any kind of connector or soldering.
My 222222 cents, (sorry for the length)
J