In one embodiment, a method of manufacturing a high voltage power fuse includes inserting a housing over a first assembly leg of an assembly frame, assembling a first terminal fabrication to the first assembly leg of the assembly frame, assembling a second terminal fabrication to a second assembly leg of the assembly frame, connecting a full-range fuse element assembly in a gap between the first terminal fabrication and the second terminal fabrication, sliding the housing over the connected full-range fuse element assembly, securing the housing in position to enclose the full-range fuse element assembly, and applying a silicated filler material to the assembled housing, full-range fuse element, and first and second terminals to establish a mechanical bond between the silicated filler material and the assembled housing, full-range fuse element, and first and second terminals.