What relays to use for Head light relays

[David Head]

One would think the post below to be series of intuitively obvious 
statements, but they are not...
Not all of us are retired nuclear electrical engineers. ;-) Or even for 
that matter marginally competent electricians.
I have 2 ratcheting crimpers from Home Depot (one for solderless 
terminals and one for RJ) and - I consider them marginal, at best. They 
also cost, as I recall, around 40+ bucks apiece. They also only do a 
competent crimp about 1/2 the time.
I've got enough relays, wiring, solderless terminals, heat shrink, 
soldering irons, flux, solder and tools to do just about damn near anything.
So for those in my camp, slap one together. Chances are it still won't 
be as nice or reliable as one from suvlights - but it will work. Cross 
your fingers and hope it doesn't decide to 'not' work at 80 plus in the 
mountains on a moonless night.

For those not in the group above, by the time you buy the tools and 
parts needed to properly construct a harness you'll pay 3 to 4 times 
what a professionally assembled one will cost.

Not to mention what your time is worth. For me, its priceless. At a 
minimum, 40 bucks an hour.

When the time comes, I'll buy 2 harnesses from suvlights.com since I've 
got 2 V8s... Plus the one on jackstands for 4 years... (actually 3 
years, 11 months and 17 days). I'll seal the connections with a dab of 
silicone to make them splash resistant.

Dave
EMCM(SW) retired
once one of 4 people in the Navy certified to crimp 4160V reactor 
coolant pump cabling.
Application Engineer
Cardinal Health - Automation and Information Services


SJ wrote:

>It costs even less to make the harness if you already have most of the
>parts.
>
>Relays can be had for free. Just pick them up at the junkyard whenever you
>pay them a visit. Junkyards do not charge you for relays. Audis and VW's
>have lots of relays in them. Through some magic process, I always find
>several relays in my pockets after every visit to the local junkyard.
>
>What? You are worried about the contacts on junkyard relays? I have not
>found a bad contact yet. Bosch relays have a double set of contacts. One set
>closes just before the second set, and likewise, they open after the second
>set opens. Any arcing is done at the "sacrificial" first set contacts. The
>relay covers come off easy enough so you can visually check the contacts.
>
>Some of us have a crimping kit . . .a ratcheting crimper and a whole bunch
>of crimp connectors. The 14 ga and 12 ga wires can be had at Home Depot. I
>would prefer to have finer stranded wires that have a good heat and solvent
>rating . . . .need to find a source for that yet.
>
>I suppose you can have the whole thing rigged up in less than an hour. I
>takes me much longer than that. I like stress loops, tie wrapped wires, wire
>protectors made from vacuum hose, a neat layout. On the second or third try,
>the time is slashed in half . . . . typical Learning Curve stuff. Now that I
>think about it, if you separate the harness making from the installation . .
>.it does take less than an hour to make the harness. The installation time
>will be the same no matter if you make your own harness or buy it.
>
>I do like those connectors that they use on the ready made harness. The lamp
>connector you can get at most auto parts stores. But where do you find the
>connector that duplicates what is at the lamp itself? Having this connector
>would eliminate cutting into the existing harness.
>
>I noticed the purchased harness had no protection for the relays. My relays
>are protected with a 1 1/2" diameter ABS plastic pipe with end caps . .
>.sealed from the weather.
>
>And last but not least, doing your own work is mentally rewarding . . . .
>the extra cash in your pocket is a bonus . .as long as the wife does not
>find it.
>
>
>SJ
>85 Dodge PU, D-250, 318, auto
>85 Audi 4k - - sold but still on the road
>88 Audi 5kq
>90 Audi 100q
>
>
>
>  
>
>>Date: Wed, 26 Nov 2003 20:17:20 -0500
>>From: "R. Mair" <waves at epix.net>
>>Subject: Re: What relays to use for Head light relays
>>To: "Quattro List" <quattro at audifans.com>
>>Message-ID: <01a301c3b484$380e9b70$06945344 at Dell>
>>Content-Type: text/plain; charset="iso-8859-1"
>>
>>$55 for a harness!?! Sheesh, for about $15 you can buy a Bosch 30 amp
>>    
>>
>relay,
>  
>
>>with plastic connector, with about 2 feet of wire already clipped into the
>>connector, AND a fuse and holder. One of these will handle either high or
>>low beams. Buy two and do both. You can have the whole thing rigged up in
>>less than an hour and the wire is heavy enough for anything you'll ever
>>    
>>
>draw
>  
>
>>through it.
>>
>>Rolf Mair
>>
>>2002 Allroad
>>1995.5 S6 Avant (for sale)
>>1995 90q Sport
>>1990 90 20v turbo
>>    
>>
>
>
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>
>  
>