Headlight Relay Kit (A More factory looking alternative?)

[78SCRSMAN]

I'm about ready for a headlight relay kit (which our host sells) but am wondering if anyone has installed the round relay holders and accompanying round "multi-purpose" relays that fit in the OE fuse block for this purpose. My car is void of extras (electric mirrors, sunroof, rear defrost, etc.) so I have a bunch of open spots.

I think it might look a bit more intentional this way so I'm interested if anyone has gone this route and can offer any tips or advice. A photo would be great too!

Thanks!

[HenrikL]

Here is a thread about that on a UK forum:

Wiring Diagram for headlamp relays using Porsche parts - Electrics - Impact Bumpers

You may need to register to see the thread.

[Algernon]

That looks fine except for 1 thing! The 2 relays each pass current to 2 filaments, which might shorten the life of the relay points. The initial surge current to 2 filaments is pretty high!
One solution would be to use 4 relays (!) if you have room.

[McLaren-TAG]

Seems like it would be easier to just relocate the kit to an inconspicuous area instead.

[porwolf]

Originally Posted by Algernon

That looks fine except for 1 thing! The 2 relays each pass current to 2 filaments, which might shorten the life of the relay points. The initial surge current to 2 filaments is pretty high!
One solution would be to use 4 relays (!) if you have room.

Agree. Did a 4-relay installation myself. Added advantage: If something goes wrong it is easier to find the culprit.

[timmy2]

I built a pair of factory style fuse bases with larger gauge wires for GeorgeK in Switzerland.
He posted about it somewhere here on the forum.
PM me if you want more info.

Edit; here it is on page 3 near the bottom.

1984 Cabrio - Long Term Project

Sent from my iPhone using Tapatalk

[Algernon]

Originally Posted by McLaren-TAG

Seems like it would be easier to just relocate the kit to an inconspicuous area instead.

Yes, inconspicuous, but not inconvenient. I put my relays next to the fuse box, where you can check the fuses without opening the box.
In fact I plan to get some fuses with tell-tale LEDs so I can spot a problem as soon as I lift the frunk lid.

[joefrantz]

I used the factory type Werle relays, wired according to this diagram originally posted by John Adams (jadams1).



Here is a link to the thread where the diagram was originally posted.

Sucro Relay Kit

Here are a couple pics of my install. Not a lot to it. I used 25 amp in-line fuses on
the battery connections just as shown in the diagram.



Mine is an older car. The top two relays in the pic below are the headlights. The bottom one is the horn.





By the way, Dennis -- your custom sockets look great.

[78SCRSMAN]

Wow, this is great everyone, thanks!
That diagram is going to be helpful too joefrantz, thanks for posting that!
I'm thinking I might be able to wire the "+" relay lead right into my fuse block since my car lacks so many accessories, I'll have to check that.

[joefrantz]

Originally Posted by 78SCRSMAN

Wow, this is great everyone, thanks!
That diagram is going to be helpful too joefrantz, thanks for posting that!
I'm thinking I might be able to wire the "+" relay lead right into my fuse block since my car lacks so many accessories, I'll have to check that.

Taking power directly from the fuse block would definitely be better if you can swing it.
I bought a second 10 slot fuse block for mine (early cars have one 10 and one 8). Now I just need to find the time to convert it.

Good luck.

[Algernon]

[QUOTE=joefrantz;8318183]I used the factory type Werle relays, wired according to this diagram originally posted by John Adams (jadams1).




Great diagram, just needs relay pins 86 and 85 reversing for safety.
Personally, I still feel happier going with 4 of the usual 100W relays, that 2 of the heavy duty 30A versions, and 4 single filament feed wires from the battery. But every solution is a vast improvement on the original, and this one looks so much nicer, like a factory original option!

[joefrantz]

[QUOTE=Algernon;8320311]

Originally Posted by joefrantz

I used the factory type Werle relays, wired according to this diagram originally posted by John Adams (jadams1).




Great diagram, just needs relay pins 86 and 85 reversing for safety.
Personally, I still feel happier going with 4 of the usual 100W relays, that 2 of the heavy duty 30A versions, and 4 single filament feed wires from the battery. But every solution is a vast improvement on the original, and this one looks so much nicer, like a factory original option!

Algernon

Regarding your comment on reversing pins 85 and 86 for safety:

Please see post # 27 in the Sucro relay discussion and also the diagram from Daniel Stern's site below.

Both of these references show pin 85 as ground, with Warren also sighting safety as the reason.

I know next to nothing about electronics, so don't take this as any kind of confrontation. I'm just trying to make sure that there is clear direction.

Can you provide more detail on your reasons for reversing 85 & 86?


Sucro Relay Kit


Daniel Stern Lighting Consultancy and Supply

[Algernon]

Joefrantz,
Oops, my mistake! I agree with post#27, and thought I was correcting an error, but it had already been corrected! I didn't look closely enough!

[joefrantz]

Thanks for clarifying.

[78SCRSMAN]

I got this done yesterday but had an issue that I was able to resolve fairly easily... I wired both the 87 and 87a together (can't do that!) thinking they were both switched power to the lights from the relay. Oops! Got it working now tho so I'm good to go! I used the fuse holder (have a few blank spots) in the OEM fuse block to protect the relays with a 16amp fuse. I know that's a bit low but I'll be installing some LED H4 bulbs that draw less current. Also installed 5amp fuses for the headlights themselves instead of the normal 8amp. Here's a thread RE the bulbs: LED plug and play headlight upgrade?