What relays to use for Head light relays

[David]

Somebody whanted to know what gauge wire was used on the SUVLights harness, so I-e-mailed them and asked, here's the response:

12 g with either 2 Bosch or Tyco/Potter & Brumfield 40 amp relays (130W bulb capacity) if you select the $55 link or 4 relays (180W bulb cap) if you use the $65 link, the $45 harness has been discontinued.

dave
87.5 CGT
SE Virginia
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From: SJ <syljay at optonline.net>
Date: 2003/11/28 Fri PM 01:33:12 EST
To: quattro at audifans.com
Subject: Re: What relays to use for Head light relays

> From: "Phil Payne" <quattro at isham-research.com>
> Subject: Re: What relays to use for Head light relays
> To: <quattro at audifans.com>

> Cut a connector off a wreck and insert copper "blades" - turning a female
into a male.  You
> just need a sheet of thin copper and some tin snips.  Then plug that into
the existing
> harness - no need to damage it.

**** I'm trying to picture this.
The existing lamp connector is female. The connector from the junkyard is
female . .exact same part.
You make 3 thin blades(copper contacts) that fit into the female contacts.
Now you have two female connectors . .back to back . .with 3 thin blades
holding the two female connectors together.

Thats not much mechanically holding the two together.
There is not much gained here. You have short wires on the end of the used
connector . .so you need more crimps to extend the wires going to the
relays.

I did something similar to my truck. The Dot headlights have large male tab
contacts. Ditto for the female mating connector.
I used 2 male tab crimp contacts to interface with the female lamp connector
for my relay signal wires. The wires were bent around the body of the female
connector and taped to it . . .for mechanical attachment and sealing.
You can use this same method for the Audi lamp connector. Except, you need
to use a dremel tool and grind the male tab contact to a size that will fit
in the much smaller female contacts.

The preferred method would be to use a male connector that would match up to
the female harness connector. The Suvlight web site shows such a connector.
Look at the blue connector in the second picture at
http://suvlights.tripod.com/suvlightscom/html/wire-harness.htm

Somebody must make these connectors.


> I'd caution also that standard in-line fuse holders aren't up to the job -
get some heavy duty
> ones.

**** Right. Use the heavy duty blade type(ATC) fuse holders . . 12 ga wires
. . good up to 30 amps. Walmart has them for about $2 each.

SJ
85 Dodge PU, D-250, 318, auto
85 Audi 4k - - sold but still on the road
88 Audi 5kq
90 Audi 100q



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