Club 80-90 Forums

tannera34 wrote:I am aware I may have slaughtered several sacred cows along the way and I may have committed electical heresy as I left the fuseboard and relay board completely alone. We use the existing wiring, relays and switches in the van and just use the feed AT the headlights to pull additional relays behind the lights to give full voltage at the lights from a heavy feed direct from the battery.

I ran a 10mm section copper cable straight from the battery with a 25A in line fuse to behind the headlight cover panel at the front of the Van. Excessive but limits the voltage drop and allows for future expansion (an extra 4 rally specials across the front perhaps?!).

This runs to two 40A relays and goes to the switched input on the relays.

The negative switching side of the two relays is run to a separate earthing point created on the bodywork (loads of choice once the cover panel is off choose something sensible). I also cut the negative wires on the headlight units (The negative daisy chains across the bulb holders) and wired those into the same earth.

Each positive switching side of the relay is fed by either the feed for the main beam or the dipped beam (find them, cut to headlight unit and feed to relay). The switched output from the relay is then wired to the appropriate headlights.

youthy giblets wrote:One thing I would like to know as I'm a tad confused, I would like to use 4mm CSa or 6mmcsa wire to feed my relays and light from the relays etc. Do the standard vw relay base accept a standard yellow crimp terminal ( yellow term being for 4-6mm wire) or is it a case of buying a genuine vw crimp terminal that will push and lock into the vw plastic relay base

youthy giblets wrote:Yes female crimps.....standard female terminals. By pigtails I guess u mean the relay base that clips onto the top of fuse box? Should have some on some golf tdi looms I think.