Eurolight conversion adaptations

[Doyt W. Echelberger]

I converted my 87 5ktq to quad rectangular eurolights two years ago, using 
a harness that I built myself and connectors from Daniel Stern 
http://lighting.mbz.org/

I rebuilt it after the first year, using heavier relays and lower powered 
low beam bulbs, because the high wattage lowbeam bulbs failed after what I 
considered a short period of service.  I retained the 100W highs because I 
seldom am able to use them, and they remained in service all year without 
failure.

The second year of experience resulted in other modifications to correct 
moisture condensation in the reflectors and deteriorating connections in 
the fuses of the circuit.  I replaced all fuses with marine-grade fuse 
holders from Ace Hardware. These are rubber devices that seal out all the 
salt spray and water that bathes the engine compartment of any car that 
operates in the salt belt all winter. I also sealed the new heavy duty 
relays in plastic bags, to protect them in the same harsh environment.  And 
I doped all the connector blocks with liquid shrink tape and used multiple 
coatings.

Then, I used the same liquid shrink tape on the actual e-code bulb 
connectors at the back of each reflector....multiple coatings.

One of the reflector units failed by developing cracks in the material that 
seals the front lens to the reflector. These cracks admitted water, which 
resulted in a quarter inch of water in the lower part of the reflector.  I 
removed the unit, examined it with a magnifying glass, located the cracks, 
widened them with a scribe, and filled the cracks with JB weld. I returned 
the repaired reflector to service and had no further trouble.  I did dry 
out the unit with a hair dryer modified to accept a short stiff plastic 
hose that fit in place of the bulb holder, with space for the forced air to 
get out of the unit. .

In summary, During two years of testing of e-code lamps, I identified the 
most significant cause of failure to be corrosion caused by water and salt 
getting into the bulb connectors, fuse holders, connector blocks, and relay 
blades,


 >>>>>>>>>>>>>>>>>>>>
At 01:02 PM 12/22/2003 +0000, you wrote:
>All right, this is starting to sound like a group buy in the making!
>Any interest?
>Mike