Headlamp wiring - H4 terminals

[syncroandy]

Any of you gurus on this subject found any suitable crimp terminals* for wire size other than 1.5mm, cos I haven't.

This isn't a problem for me as I have no desire to use a non-standard size, but for those that have, I was wondering if you'd found a 'correct' terminal, or is some sort of 'magic' involved ?

I'm just building a fresh front harness along the lines of the Carat one, with extra wires back to the relay plate for the inner main beams and the extra horn. BTW the Carat one is only £130ish new iirc.

PS. * H4 terminals for the VW housing that is.

[AdrianC]

Plenty of bulbholders on the 'bay cheap nuff - with lengths of wire to allow you to take 'em to some kind of proper connection point.

http://www.ebay.co.uk/itm/271410473761" onclick="window.open(this.href);return false;
I had a couple for the now-deceased Shogun (ridiculous light wiring, with shared +ve feed and switched earthing!) - decent enough quality.

[CJH]

I used a replacement bulb connector, which used 'flag' connectors, and although they're meant for 1-2mm2 cable I was just about able to crimp and solder some 4mm2 cable into them.

But the VW housing (on mine) uses straight 8mm female blades, presumably with latches to keep them in the housing. Maybe FBL8 on this page would do the trick. They're 7.7mm wide, so would probably fit the bulb, and they're intended for 2.5mm2 cable, so would probably go bigger if you solder as well. The next size up, FBL9, takes 4mm2 cable, but at 9.5mm would probably be too big for the housing.

[AdrianC]

I used a replacement bulb connector, which used 'flag' connectors, and although they're meant for 1-2mm2 cable I was just about able to crimp and solder some 4mm2 cable into them.

But the VW housing (on mine) uses straight 8mm female blades, presumably with latches to keep them in the housing. Maybe FBL8 on this page would do the trick. They're 7.7mm wide, so would probably fit the bulb, and they're intended for 2.5mm2 cable, so would probably go bigger if you solder as well. The next size up, FBL9, takes 4mm2 cable, but at 9.5mm would probably be too big for the housing.

Given that 2mm2 cable is good for 17.5A, do you need bigger? That'd be a 210w bulb at 12v!
http://www.vehicle-wiring-products.eu/V ... dcable.php" onclick="window.open(this.href);return false;

[CJH]

Given that 2mm2 cable is good for 17.5A, do you need bigger? That'd be a 210w bulb at 12v!
http://www.vehicle-wiring-products.eu/V ... dcable.php" onclick="window.open(this.href);return false;

No, you're right. But remember it's not just about current rating, it's also important to minimise the voltage drop. But again, 2mm2 will drop next to nothing at the currents we're talking about for headlights. See here.

[AdrianC]

Given that 2mm2 cable is good for 17.5A, do you need bigger? That'd be a 210w bulb at 12v!
http://www.vehicle-wiring-products.eu/V ... dcable.php" onclick="window.open(this.href);return false;

No, you're right. But remember it's not just about current rating, it's also important to minimise the voltage drop. But again, 2mm2 will drop next to nothing at the currents we're talking about for headlights. See here.

Ohms per kilometre... <chuckle>

[CJH]

Ohms per kilometre... <chuckle>

530km of wire in an Airbus A380 apparently. I wonder how much that weighs.

[syncroandy]

Cheers chaps, I think that's a 'no' so far except for FBL8.

I'm using Wurth 0558 502 0. The VWP part will probably be similar so may be an option, though TBH I avoid VWP (and Polevolt) these days as I find their quality a bit random.

[lloydy]

Have you tried this place Andy? Been using them for most of my stuff
http://www.altecautomotive.co.uk" onclick="window.open(this.href);return false;

[syncroandy]

Cheers Lloyd, I'm sorted for the terminals I need thanks, it was more a query for info really.

[ELVIS]

Doing a google search and found this thread

Same problem Andy Looking for 8mm Latched terminals but bigger than usual suppliers as wanting to run a second wire out for SA inner lights. Ideas chap?

[syncroandy]

Hi chap, I'm still using the Wurth parts which are top quality and perfect for the job, but their size precludes using them to join two wires in the crimp if that's what you want to do. Nowadays when I add connections for inner spots I run a separate pair of wires for each back through the front harness to the relay plate and splice them in there.