And then there was light.....

[Doyt W. Echelberger]

My old Audi doesn't have bad lights anymore. The 1987 grill and turbo
headlights are off, and in their place is a quad light system from a 1985
Audi 5000.....with e-code lamps running off relays. The resulting 200 watts
of low beam show a whole new world at night, with sharp cut-offs and
courteous treatment of oncoming drivers. The 400 watts of high beam make
the road ahead remarkably visible. So far, I have only tested the system in
good clear weather.

The mechanical swap went easily. I wired two 40 amp relays using 10 gauge
fine strand copper, starting with ring connectors from the jumpstart post.
The post easily backed out like a bolt, and I cleaned it up with a Dremel.
Each circuit has a fuse between the post and the relay.

 From each relay, I ran more 10 gauge to each headlamp. I used a 4 hole
distributor block from a stereo store to feed the 4 high beams.

I used a similar distributor block to supply grounds to each
lamp......again, using 10 gauge stereo cable.  From the ground post of the
battery under the rear seat, I ran a 10 foot long 8 gauge cable to a 4 hole
ditributor ground block behind the passenger headlamps. It followed the
cabin floor under the carpet to the firewall. There was a nice big unused
port in the firewall behind the glove box, and I just popped out the rubber
seal and threaded the cable from inside the cabin, grabbing it when it
showed at the port in the bay behind the engine. Had to open up the thin
plastic rain shield over the bay. There were more leaves in there than I
expected. I threaded the cable out into the engine compartment at the same
place that the washer fluid hoses use. Then, I snaked the cable along with
the many vacuum hoses that populate that area, and brought it out behind
the passenger side headlamps, where I connected the 4 hole distributor
ground block.

That completed the power side of the relay system. I snipped off the old
wires that supplied the passenger headlamp bulb, and used the yellow wire
to control the low beam relay.  I used the white wire to control the high
beam relay, and I used the original brown ground wire to supply both
control circuits in the two relays. Now my control circuits carry very
small currents, and the multifunction switch on the steering column no
longer heats up and makes melting noises and smells.  I replaced that
switch a few months ago when the headlamp components in it melted, and this
was one of the motivators that sent me to the quad light relay system solution.

In summary, I now have very adequate lights.  Thanks to all you people who
assured me that quad lights could be fitted and upgraded to do the job. The
secret is the e-code reflectors and the relayed power supply. Daniel Stern
supplied the e-code components and the schematics. Taka assured me it would
be a big improvement. Dave Conner offered considerable support. Nick
Lawrence actually supplied the quad lamp system, and, Huw Powell walked me
through the rewiring. And many of you wrote well in the archives about your
journeys to better lighting.  Thank you all. Those who wrote about needing
the parts that were left over from the conversion, please email me with
firm offers for the parts you need, and say where you live. I will try to
respect the timing of your original inquiries, and might even end up
sending you the parts you need most and can't find anywhere else.

Doyt Echelberger
well-lit and smiling in Ohio