Non-T25, but perfect for a time-served VW mechanic

[CJH]

I've been helping a mate to wire up a beach buggy, based on a 1967 Beetle. It has the Beetle steering column and stalks. Everything seems to work as it should, apart from one little detail. The headlight main beams only come on while the indicator stalk is pulled towards you. They go off if you release the stalk, so there's no way to make them stay on.

We tried pulling the stalk harder, or pushing it away, but there's clearly no way to make it mechanically latch in the on position. So I can think of two ways that the original system might have worked.

1) Perhaps there was a separate switch for the high beams - maybe a floor-mounted foot switch - but I can see no mention of this in any of the user manuals from that era.

2) Perhaps the original dimmer relay was a latching type. We've used a simple change-over relay, but if there was a latching change-over relay then the stalk would just toggle between dipped beam and main beam. It would mean that there was no simple 'flash' mechanism, as any operation of the stalk would toggle the relay, so to flash your lights briefly you'd have to pull the stalk twice.

Can anyone confirm how the Beetle main beams worked?

[bigherb]

It should have a headlamp relay that switches over from dip to main beam just by pulling the stalk back and releasing it. Main beam will come on when pulling the stalk back as it always works the flash function. If you have dipped beam working then it is a faulty relay.
Yes the original relay throws a mechanical switch over inside the relay.

[CJH]

Thanks Bigherb - yes, currently we have a changeover relay that requires the trigger circuit to be made via the stalk*. I wouldn't say it's a faulty relay, just the wrong sort. So with a latching headlight relay, one pull on the stalk will toggle the main beams on, the next pull will toggle them off. That much I understand, but I don't think I follow this sentence:

Main beam will come on when pulling the stalk back as it always works the flash function.

As I understand it, if the main beams are off, pulling the stalk will turn them on until the next pull of the stalk. How is it possible to work the flash function without pulling the stalk twice?

*The NC circuit is the dipped beam, the NO circuit is the main beam.

[bigherb]

Main beam flash is a separate switch inside the relay that always closes when the stalk is pulled back. The flash contacts are fed independently by a permanent live supply. The changeover contacts are only supplied when the head lamp switch is on.

The original relay is wired.
30 permanent live for headlamp flash contacts.
56 live when headlamp switched on .
56a to dip beam.
56b or F to main beam.
S earth via dip switch.

[CJH]

Ah, got it, thank you. I hadn't thought about the flash function when the lights aren't on. It's all clear now. Thanks again.

[CJH]

This is a bit of the wiring diagram that we've been following, showing the dimmer relay 'J'. There's no '30' supply, just the (switched) '56' supply, so does this mean the original Beetle didn't have the flash function?



Here's the full wiring diagram, but it's clear that the headlights only get their power from that relay, and that relay doesn't have a permanent live supply. Is the flash function required for an MOT? I guess the solution is to look for an updated relay with a '30' terminal and add a permanent live to the circuit.

[marlinowner]

Headlight flasher is not required for MOT. If keeping original registration / date of manufacture then hazard lights, fog light not required either.

https://docs.google.com/viewerng/viewer ... _guide.pdf" onclick="window.open(this.href);return false;

[bigherb]

Don't use yank wiring diagrams they have too many differences to European models.

J is the headlamp relay

http://www.thesamba.com/vw/archives/inf ... Wiring.jpg" onclick="window.open(this.href);return false;

[CJH]

Thanks gents. I think the solution then is to replace the simple change-over relay that we've used with a proper latching headlight relay, and even though the flash function isn't required for the MOT it will be simple to run a permanent live to that relay to add this function.

Thanks all.

[CJH]

We wired in the proper headlight relay, and now it all works as expected. When the lights are on, the stalk toggles between dipped and main beam, and during the day the stalk works the flash function. So now my mate's buggy has the same 'feature' as my T25 - if he flashes his lights an odd number of times during the day, his lights will come on in the main beam setting at night.

We've got another question - I hesitate to ask it here as it's nothing to do with electrics, but it still suits the thread title. We haven't had it moving under its own steam yet, but it seems like the gear change has a traditional 'H' pattern, with reverse to the left of second. The odd thing is that the gearstick doesn't need to be pushed down to reach the gear that's in the reverse position, but it does need to be pushed down to reach what we think are third and fourth. Beetle manuals suggest the push down is only needed for reverse, as a safeguard against accidentally selecting it. We understand that the buggy has a gearbox from a 1300 Beetle - is it possible that the linkages have been assembled wrongly, to put the reverse detente on the wrong side of the gate?

[bigherb]

to put the reverse detente on the wrong side of the gate?

I expect the lower plate under the gear lever is the wrong way round. The detente with the upward curve should be to the right

[CJH]

Thanks Bigherb - that sounds simple enough. We'll check that.

[CJH]

I expect the lower plate under the gear lever is the wrong way round.

That's all it was, thank you. My mate's now sorted it out - just a couple of bolts to undo, and an adjustment procedure that's described in the Haynes manual, and it's all good now.

I found this photo on a thread in the Samba - it's from the American Bentley manual, so substitute "Left" for "Drivers" and it works internationally!