[Vwdiesel] SilverStar headlights-more-long

[Doyt W. Echelberger]

My suggestion for the 1991 Jetta is that you consider regressing your 
headlight system a few years, back to the rectangular quad-light system 
that ended with the 1984 Jetta....and then fit the quad rectangles with 
euro bulbs.  I had rectangular quads on my 82 diesel Jetta (and I THINK VW 
used quads in 1981, 1982, 1983 and 1984.)  I did a regression on a 1987 
Audi, from the aerostyle single module back to the quads that were used on 
the 1985 Audi 5000, and then I swapped in Euro Lights and use Euro bulbs 
instead of the DOT quad rectangular lenses and bulbs.

This is a web site that will help you do that, with background and parts:
<http://www.danielsternlighting.com>

I also rewired and relayed the system, using #12 stranded wire and 
connectors and branch blocks from an auto audio store.  My headlight switch 
on the dash no longer carries the full current of the headlights. It never 
gets hot, and will outlast the car.

In the year following the rewiring, I discovered that the connectors needed 
to be marine grade, because the ones I used allowed salt spray from winter 
roads to get into the wiring, and it caused failures.  So, I suggest 
starting the whole rewiring process using marine-grade connectors.

The quad euro lights gave me a vast range of wattages to pick from, and I 
tried various combinations, up to about 100 watts for the highs, and 
discovered that the very high wattage bulbs didn't last very long...maybe 8 
months....whereas  The lower wattages (about 55 watts) lasted for years.

And using the retrogressed quads (on the Audi) cut my total cost in half, 
compared to any other option. The result was an AMAZINGLY bright 
illumination of the road that lit things up half a mile ahead when I used 
the short-life 100 watt lamps. I really didn't need all that light, but it 
was very rewarding to be able to have it as an option, in case I wanted to 
enter night rallies :~)

Personally, If I wanted to save money, I'd just rewired and relayed the 
stock 1985 Jetta aerostyle system, for a very significant increase in 
ability to put light on the road.....but I'd use much heavier wires, 
marine-grade connectors, and not ignore the size of the wires on the ground 
side.....I'd make them equal what I did to the positive side.  And if that 
didn't light up my night, I'd go to a quad system and run it off the new 
wires and relays.

Doyt Echelberger
1985 Jetta TD

PS: Here is something from my file, written in 1999 by Mark Pollen, on 
weatherproof relays:

"Not too long ago I ordered and received from Hella (free of charge)
their relay catalog (among others).  In the relay catalog they have
weatherproof relays/connectors for the standard pin configuration.

The 20/40 amp *weatherproof* relay *with bracket* is part number 66211
The *weatherproof* connector is 87173

Hope that helps somebody building their own harness, etc.

Regards,

Mark Pollan, '86 5KCSTQ 274K Miles

P.S.  Hella's phone number is 800-247-5924"

 >>>>>>>>>>>>>>>>>>>>>>>>>
At 08:22 AM 12/16/2006, Nick wrote:>

 > Has anyone upgraded their headlights to the SilverStar's?  I have read good
 > and bad online about them. ....snip...... :-( I was considering
 > HID's but they are a little out of my price range right now. I found the
 > conversion kit for around $250.
 >
 > Nick