I added an EXTRA ground just behind each headlight by tapping into the
ground wire, I drilled a hole right there to ground it.
It's a VW, an extra ground will not hurt.

Rob
vwrobb@gmail.com
On Sep 3, 2014 11:49 AM, "Jon VonOhlsen" <jondvo@gmail.com> wrote:

> Just to confirm, adding a relay kit such as from Bus Depot, GoWesty &
> others is a good idea. the wiring will provide adequate current for the
> 55 - 60W bulbs, but the voltage drop on the headlight switch is
> eliminated with the relays.
>
> Also don't forget the ground cluster under the dash on the drivers side,
> this is a round connector assembly with ground connections around the
> diameter. Good to clean & remove oxidation , etc. This step, along with
> the relay kit, has my stock bulbs working great.
> I did replace the headlight lenses and adjusters, and make sure the
> headlights bulbs are CLEAN, only touch with non-lint cloth.
>
> The round headlights with the relay kit are the best, but also $$$, the
> SA kit is pricy.
> Jon
>
>
> On 9/2/2014 8:19 PM, KIM BRENNAN wrote:
>
>> Dennis covers some aspects. I’ll add to his comments.
>>
>> Adding high wattage bulbs is almost certainly your worst choice. You are
>> dealing with old wiring, in addition to (most likely) old headlight
>> housings. Even with relays, the old wiring in your bus just isn’t designed
>> for more than the standard 55 watt bulbs. Using relay allows you to bypass
>> sending the current through the difficult to obtain headlight switch and
>> prevent you from melting that, but the rest of the wiring is still 23 years
>> old, at best.
>>
>> Regular round sealed headlights are actually very good, and much better
>> than the rectangular DOE headlights on our Vanagons. The Eurospec
>> rectangulars were much better, but have a very sharp cutoff, which some
>> people do not like. Even the eurospec round headlights can have a very
>> sharp light cutoff, which makes some people uncomfortable.
>>
>> If you can afford the price, and can source the round headlight aiming
>> assembly, the South African Round Headlight grill/lights with standard
>> sealed beam round headlights are your best choice.
>>
>>
>> On Sep 2, 2014, at 9:39 PM, Dennis Haynes <d23haynes57@HOTMAIL.COM>
>> wrote:
>>
>>  A number of folks have mentioned upgrades and many of them work well. The
>>> first problem you have is that you existing headlight assembles are shot.
>>> The lenses are pitted on the outside from road stuff and speed and the
>>> reflectors even if they "look" OK no longer do what was designed. Simply
>>> replacing them will do wonders. Unfortunately they are no longer
>>> available.
>>> Neither are the European versions.
>>>
>>> Installing high power bulbs just increases the brightness of the poor
>>> light
>>> distribution and even if you don't get flashing light complaints from
>>> oncoming drivers those you follow can also be annoyed at the bad light
>>> pattern. Going to the earlier round lights with standard wattage, high
>>> performance bulbs is a good choice. The South African grill and lighting
>>> is
>>> a great choice if you do a lot of driving where you need really good high
>>> beams.
>>>
>>> Dennis
>>>
>>> -----Original Message-----
>>> From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf
>>> Of
>>> Maureen
>>> Sent: Saturday, August 30, 2014 5:55 PM
>>> To: vanagon@GERRY.VANAGON.COM
>>> Subject: Headlights
>>>
>>>  Hi folks, I'm looking for advice on headlights. Mine are dangerously dim
>>>>
>>> at night, can I just put in new higher power bulbs or do I need to
>>> install a
>>> whole kit including new wiring? I have a '91 Vanagon.
>>>
>>>> Thanks,
>>>> Maureen
>>>>
>>>>