Headlamp relay updrade/mod

[ScienceBoy]

Can anyone recommend relays and/or retailers of choice?

[Cruz]

30amp/40amp standard switching relays from ebay which are cheap or even relays with built in blade fuses

[California Dreamin]

These guys will sell most of what you want but you may find yourself ordering a few bits from other places.
http://www.autoelectricsupplies.co.uk/" onclick="window.open(this.href);return false;

The basic list of parts I used to do the full mod was:

2 X standard 4 terminal relays like these:
http://www.autoelectricsupplies.co.uk/p ... ategory/36" onclick="window.open(this.href);return false;

5 - 6 meters of 42 amp cable and a meter of 17.5amp for the switching side of the relays and a about 4 metres of the 27.5amp to use from relays to dip/full beam on the bulb holders.
http://www.autoelectricsupplies.co.uk/p ... ategory/11" onclick="window.open(this.href);return false;

2 bulb holders
http://www.ebay.co.uk/itm/NEW-BULB-HOLD ... 2a21f5f6c0" onclick="window.open(this.href);return false;

Two heavy duty fuse holders for the two feeds from the battery.
http://www.ebay.co.uk/itm/MAXI-BLADE-FU ... 20c8596e98" onclick="window.open(this.href);return false;

A weatherproof box....
http://www.ebay.co.uk/itm/GEWISS-IP44-J ... 416396003a" onclick="window.open(this.href);return false;

various 6.3mm spade connectors (yellow for the larger cable blue for the smaller)
yellow 6mm eyelets for the two earths.

Martin

[what2do]

Do you have a crystal ball? My next question was going to be about a shopping list. Miraculous, go on - tell everyone what's on mind right now!


A description of the route from the battery to the front of the cab would also be appreciated. Cheers.

[California Dreamin]

All I can do is describe how I did it, others have taken the feed from the main fuse box feed...the choice is yours.

I took the two feeds straight out the bottom of the battery box through the installed grommet...under the floor (cable tying to anything solid) and then up around the bulkhead behind the offside headlamp cluster (around 2.5 metre run)
You might want to use shrink rap sleaving or insulating tape for extra protection, heavy duty fuse holders close to the battery.

Martin

[ScienceBoy]

What're the bulb holders for, replacements for what was there, or a base for the relays?

[California Dreamin]

Like I say....depends on how you want to do this...personally I would just solder on spade connectors and push them directly onto the relays..however, you might want to fit sockets like these:

http://www.ebay.co.uk/itm/Black-Relay-B ... 20c5aa28e2" onclick="window.open(this.href);return false;

The bulb holders I have listed REPLACE the originals as in my mod I don't cut the original wiring at all, I leave it completely intact and push 'MALE' blade terminals into the original bulb holder to take my switching feeds (dip & full beam) to the new relays as triggers, then just tape the whole thing up as neatly as possible......
This way you can always revert back to the original setup if something goes really wrong.

The H4 bulb holders solder onto the NEW wiring coming from the relays (don't forget to loop over from the full beam feed on the H4 to the full beam H1 bulb holder terminal) if it's a 4 lamp setup....nice thick wire.

And again...nice thick wire for those two earthing points each side...using eyelets. I made a seperate earthing post behind each light cluster with a 6mm bolt/3 nuts and earthing washers taking the bolt hole back to bare metal and painting once done.
Solder where you can, better than just crimping.


Martin

[ScienceBoy]

The bulb holders I have listed REPLACE the originals as in my mod I don't cut the original wiring at all, I leave it completely intact and push 'MALE' blade terminals into the original bulb holder to take my switching feeds (dip & full beam) to the new relays as triggers, then just tape the whole thing up as neatly as possible......
This way you can always revert back to the original setup if something goes really wrong.

Brilliant

[what2do]

Would be nice to see a pic of the new earth posts if anyone would like to appease me! Thanks ever so much, Mitch.

[ScienceBoy]

from memory the wire it's a white wire with a yellow strip that is used as switched live feed from the fog light switch for the front fogs
neil

So you didn't use the relay in the fuse box (7?) and used local relays like above?

[California Dreamin]

I had to do a little running repair...basically replace a cheap 40amp relay I bought off ebay as it would occasionally stick (as with all things, you get what you pay for) Anyway...here is the picture of the offside earth (there is an identical earth post on the Nearside) the hole is already there, you just scrape it back to bare metal, fit a 6mm bolt & nut to fit your eyelet. I just rattle canned it with some silver 5 wheels to prevent it rusting.

Other pictures showing the relay box...not the neatest of wiring because I've left the original wiring UNTOUCHED and just used the socket to switch feed the relays.

One of the earths




Changing a relay (had to replace two of the spades for the larger 9.5mm ones) New heavy duty relay is the lower one.




A bigger pic






Altogether with the lid on the box



Hope this helps .....

Martin

[syncroandy]

Parts list:

2 off VW 161 937 501 B relay plate
2 off VW 141 951 253 B no. 53 relay
~8 1/4" lucar terminals
some wire

Best quality and value parts IMO are recycled VW bits from your local scrapyard. I'd rather use a 15-year old gen VW relay than some chinese cr*p off Ebay..

[California Dreamin]

Agreed, I just didn't have any 40 amp relays at the time, quite a few good quality 30's .

The one I've used now is a 60amp with larger MAIN feed terminals borrowed out off a Toyota (japanese quality)

Martin

[lloydy]

What are the issues a cheaper relay will give you? Just more likely to fail? Or something else?

[syncroandy]

I've just got very mistrustful of non-OEM parts in general, IME its very common they are substandard in some respect and so I just avoid them now if at all possible.