Nothing wrong with running a separate wire from the battery just for
headlight relays. My Baja Syncro is currently wired that way and I did
that on some other peoples vans too. That does not really solve much
more than just the TK relays do on later models as the major voltage
drops are after the fuse panel anyway so the TK relays fix most of it.
Be sure to run new headlight grounds as long as you are at it.

The 'Terry Kay' kit provides most of the voltage gains that are to be
had and is a clean factory type solution. Anyone versed in auto
electrics can make a similar or even better setup. I only pointed it out
because it works well and a relative novice can do it. It is also
something I would feel good about leaving in on a vehicle I later sold.
The direct battery connection approach also works well but might leave a
future owner grasping for answers as to how to troubleshoot a lighting
problem. The TK setup uses factory parts and wiring colors. It also
mounts right to the relay panel where anyone working on the system would
find it. All of the stock fuses still do the same things. VW should have
done it that way from the start.

Mark

"Walker, Phil" wrote:
>
> Seems like this would be a good kit, but it still doesn't solve the problem
> of getting power directly from the batteries. If I'm going to put that
> wiring in place, I think I might be just as easy to wire up the whole thing.
>
> ....

> -----Original Message-----
> From: mark drillock [mailto:drillock@earthlink.net]
> Sent: Monday, March 22, 2004 5:01 PM
> To: Phil Walker
> Cc: vanagon@GERRY.VANAGON.COM
> Subject: Re: Headlight Wiring and Relays
>
> Terry Kay, long time list member, sells a really sweet headlight relay
> kit for $30. The wires are the right matching colors and it installs
> cleanly to the 86+ relay panel. It uses genuine 2 VW relays and 2 relay
> sockets and it retains the stock headlight fuse layout. Instructions
> included.
>
> I have bought a few kits from him and he also has them on Ebay.
>
> http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&category=33708&item
> =2467958251
>
> Mark
>
> P