Relays install

[Aleksander Mierzwa <alex@matrix.pl>]

Hi List,

I finally found the time to install relays for my Euro headlights on the
5KT. Before that, I was getting only 11.5 volts to the bulbs - needless to
say, the light output was very unimpressive. I used two relays and two
inline fuses for each headlamp, which are installed in two plastic
enclosures (not watertight, though, I may want to seal them with RTV or
something later) mounted directly to the back of the headlights - this way
I minimized the lenght of the wires between the relays and the headlamp
connectors. The respective pairs of relays are fed by two 2.5mm wires going
from the jumper post. Before doing the modification, I decided that I do
not want to lose the "bulb out" indicator. To accomplish this task, I moved
the bulb monitor into the LH relay enclosure and ran the "sensor" wire
through the firewall. The wire from the RH relay runs to the LH enclosure,
passes through the bulb monitor and goes back to the RH headlamp. The bulb
monitor is wrapped in insulating tape, as it is probably more sensitive to
moisture than standard relay. 
It is a time-consuming job if you want to do it properly. I soldered most
of the wire connections for reliable, weatherproof operation, used proper
5-point relay connector boxes, tie-wrapped the wires going from the left to
the right of the car to the factory wire loom etc. I may still want to go
back there this weekend, since I'm pretty much paranoid about possible
failure/shorts of any aftermaket wiring in the car. Anyway, now I'm getting
13.3 volts at the bulbs and the light is finally _bright_.

Aleksander Mierzwa
Warsaw, Poland
mailto:alex@matrix.pl
87 Audi 5000CS turbo (mine)
88 Renault Medallion wagon (mom's)
91 mountain bike (just in case both cars break at the same time :-)