Overheating fuses is either a sigh they are being used to close to their
limit or there is a connection problem. The most important information you
left out is the wattage of the bulbs you are using. Some folks have
questioned the wiring but they may be wrong. Most of the relay kits are
designed to reduce the losses from the ignition and head light switches. You
need fuse or other over current protection. Light bulbs can and do fail
where they short out. That is why European cars use separate fuses for
right-left side and high-low beams. Have a bulb short, blow the fuse, other
side still lighted. Our taillights are the same way. American vehicles use a
self-resetting circuit breaker usually part of the headlight switch. Short a
bulb, flash the lights so you don't go fully dark and hopefully the short
will clear and the remaining light can stay on.

If you are using 80/100 watt bulbs for low beams and 100 watt bulbs for high
then you will have wiring problems especially if using the original fuse
box. 400 watts is >33 amps at 12 volts. More than 1/3 or your alternator
capacity. You need to look at the entire current path from the alternator,
(not just the battery) to ensure it can carry this and all the other loads.
From the lights you should be running 12 gauge. To the relays (feed) at
least 10. 8 would be better to reduce the voltage drop. Consider 6 or 4
gauge from the alternator to the battery cable at the starter. Then from the
battery run a parallel gauge to the fuse box and tap this for the headlight
feed.

Dennis

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
Mike Saint-Amour
Sent: Wednesday, January 20, 2016 9:24 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Headlight relay kits

Group

I purchased a headlight relay kit a few years ago.  Recently I have been
challenged with the issue of heat on fuses 5 and 6 when using the high
beams.  Fuse 6 even melted once.  Everything works fine as long as I don't
leave the high beams on for long.   Do you know what would cause that
problem?   Do I need to replace the relays?  Change wiring?   My kit was
from Vanagon westfalia parts.

Go now.  Because later has a terrible habit of becoming NEVER.
Anonymous

Mike Saint-Amour
www.slowcarfasthouse.com

Go now.  Because later has a terrible habit of becoming NEVER.
Anonymous

Mike Saint-Amour
www.slowcarfasthouse.com