The primary purpose of adding headlight relay is to
remove the headlight switch from the current path of
the low-beam headlight circuit to keep it from
melting. Typically, the switch will cause a 1 volt
drop when measured across the switch. A relay can be
added for about $5.00, you'll need one 30A relay, some
terminal lugs and some wire.

The effectiveness of 9004 bulbs (no matter what
wattage) is limited by the design of the reflectors in
the Vanagon headlamp housing. Don't oversize the fuses
in order to gain more light output unless you upgrade
all of the wiring - fuses are sized to protect wiring,
not components.

If you want to keep the rectangular headlamps and not
add any additional lights, the e-code headlamps are
the way to go.

An auxiliary low-beam light like the Hella XL is
another alternative.
<http://www.rapidparts.com/Pages/vwc030p.html> They
are designed to supplement the stock low beams and are
legal for that purpose. The kit comes with its own
relay and is easy to install.

I have had a set for a couple of years now and am very
happy with the setup.
<http://home.earthlink.net/~tjhannink/photos/4-23-02_In_Park.jpg>

A wiring diagram for my headlight relay and the Hella
XL's is here.
<http://home.earthlink.net/~tjhannink/Hella_XL_Driving_Lights.htm>

Good luck,

=====
TJ Hannink
Goldibox - 1987 Vanagon Camper, Wolfsburg Edition
Winter Park, Florida
http://home.earthlink.net/~tjhannink/
http://groups.yahoo.com/group/wolfsburg_campers
http://photos.yahoo.com/tjhannink [Vanagon] Album

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