Use 2 good quality relays, with mounting tabs. One for low beams, one
for high beams. Mount them above the glovebox. Control them with a leads
from the existing low and high wires to the pass side headlight. Power
them via a direct feed #8 from the battery to a 4 fuse panel mounted
next to the relays. Ground each headlight right at the headlight buckets.

I have done this a few times and the increase in brightness is
substantial. This works better than how the various vendor kits though
it requires more work and more parts.

By the way Neil, there is no stock hi/low relay.

Mark

neil n wrote:
> Hi all.
>
> Preface: not trying to reinvent the wheel here. I know lots have done
> the relay upgrade. My reasoning is below.   :)
>
> I've been enjoying my new "Motorcycle" E4 headlights on my '81. Even
> with stock wattage bulbs, it's a huge improvement over sealed beam
> rounds. But I need more light!
>
> Thought: install new switch and dedicated circuit, (no added relays),
> bypass ignition switch, use stock hi/low relay, connect supply of
> circuit in at stock connectors to headlights.
>
> Added work aside, is there anything inherently wrong or illegal, about
> doing this? Would I "simply" tap into 30 where it enters pre fuse at
> the fuse box? (adding inline fuses of course) What gauge wire for the
> next step up in lighting?   (I bet that info is online somewhere)
>
> I used to do a lot of road gigs in a '77 Caprice with upgraded
> headlights. Amazing, but relays would cack out at THE worst moments
> (before a corner) This stuck in my mind, so thought to make a system
> that didn't rely on relays. Likely the installation was faulty on the
> Caprice, but it would be my preference to make a "bulletproof" system.
> Like all that could fail would be the switch, fuse(s), stock hi/low
> relay and switch  ..... I think   ;)
>
>
> Neil.
>
> --
> Neil Nicholson '81 VanaJetta 2.0 "Jaco"
>
> http://tubaneil.googlepages.com/
>
> http://groups.google.com/group/vanagons-with-vw-inline-4-cylinder-gas-engines
>