I've put relays and 80/100w bulbs in my system (OE vanagon lights). I've
replaced the passenger side plug 2 times since this modification. I made new
grounds with larger wires to both grounds and power, and that has (so far)
eliminated my overheating problems. I ran short ground wires to the steel
"firewall" directly behind the lights. I also have Hella 550 "high beam"
lights on my bumper, which really turn night into day out in the desert
night. They automatically come on with my high beam switch. It sounds to me
like you have a lot of resistance in your system, which may be coming from
poor grounds?
Bob
'87 Syncro Westy

On Sun, Jun 7, 2009 at 10:05 PM, Michael Hart <mjhart853@yahoo.com> wrote:

> I the SA Grille with high pwer headlight kit installed in my '87 Westy [SA
> Grille, relays, lots of additional wiring & 80/100W bulbs (outer lights) &
> 100W bulbs (inners) (done approximately 2 years ago). I used the high power
> headlight kit from 'a well known on-line vendor'.
> Whilst checking fuses today, I found that one of the relay connector blocks
> (high beam relay) had melted pretty badly and the wires were very
> discoloured. Running the high beams, the wires and connector block got very
> hot (& it was only 70F today) within a few minutes use. Just as well that I
> haven't used high beams all that much since I did the install!!
> Apparently 400W of light (34A) is too much for these connectors.  I also
> found that the wires leading into the inner high beam units also showed
> signs of too much heat (these wires are just a few inches long, after that I
> had installed major wiring back to the relays). I have put the original 55W
> bulbs into the inner high beam units, reducing the total load to 310W (26A)
> at which point wire & connector temperatures seem more reasonable (yet still
> quite warm).
> I followed all the vendor instructions exactly, but it seems to me that
> perhaps 400W is over-rating the kit (of course, I do like the major
> improvement in lighting).
>
> Has anyone else seen problems like this??
>
> Thanks,
>
> Mike,
> 87 Westy
>
>
>
>
>