Hello!
Sorry for the late update here.
I had this idea of installing relays in the circuit but never got around
doing it. However ever since I changed the headlight switch and a wire
things are cold (literally!) now. The switch escutcheon doesnt heat up like
before, neither do I smell burning plastic. So I guess the issue is solved
at least for the time being. But I guess I should move asap and put the
relays lest I damage one more headlight relay.
Regards
Asad
Karachi, Pakistan.
>From: "Bill Smothers" <[EMAIL PROTECTED]>
>Reply-To: Air-Cooled Volkswagen Discussion List <[email protected]>
>To: "Air-Cooled Volkswagen Discussion List" <[email protected]>
>Subject: Re: [vintagvw] 68 bug Headlight problem
>Date: Fri, 24 Aug 2007 08:05:32 -0400
>
>If you are running Halogen headlights or similar, they require more
>amperage
>to function which in turn has the tendency of causing overheating. The
>overheating in turn leads to premature failure of the switch. The 356 guys
>solved the issue by installing relays in the hi/low beam circuits. You
>might
>try that approach
>Bill Smothers
>65C 219655
>Charleston, SC
>----- Original Message -----
>From: "asad ishaque" <[EMAIL PROTECTED]>
>To: <[email protected]>
>Sent: Friday, August 24, 2007 6:52 AM
>Subject: Re: [vintagvw] 68 bug Headlight problem
>
>
> > Volks,
> >
> > I had fit a brand new headlight relay earlier for the probs I
> > described.
> > Still there was a smell of overheating while driving the bug at night.
> >
> > 'Investigation' while driving revealed that the headlight escutcheon
> > was heating up.
> >
> > Took the trouble of some more tinkering today. Found this:
> >
> > The wire connectors going from terminal 56 of the headlight switch
>to
> > terminal 56b of the relay was heating up. In fact the plastic clips on
> > both
> > ends were melting up and turned to globs.
> >
> > Rummaged thru my parts bin to find another good headlight switch.
> > Cleaned it up and installed. (had noticed that there was a slight amount
> > of
> > rock in the previous switch's terminal 56). Still heat. Then took a
>fresh
> > piece of wire, crimped new clips at both ends and installed. Made sure
> > clips
> > were tight n snug.
> >
> > Well after this the wire still heats up but not as much as before.
> >
> > I may get shot by the people for not revealing this earlier but Im
> > running higher than stock wattage bulbs for the heads. Could this be the
> > source of probs???
> >
> > I am now thinking of having another aftermarket non vw relay working
> > with the original relay for switching on the headlights. Would that make
> > life easier??? Can people suggest where I should put that assuming its a
> > good option.
> >
> >
> > Waiting for input.
> >
> > TIA
> >
> > Asad
> > Karachi, Pakistan.
> >
> >>From: "asad ishaque" <[EMAIL PROTECTED]>
> >>Reply-To: Air-Cooled Volkswagen Discussion List
><[email protected]>
> >>To: [email protected]
> >>Subject: Re: [vintagvw] 68 bug Headlight problem
> >>Date: Wed, 08 Aug 2007 11:40:19 +0000
> >>
> >>Hello Chuck,
> >>
> >> The loose terminals were on the relay, so I guess the probs
>fixed.
> >> I
> >>will however check for any hot spots as described by another member
>here.
> >>
> >> The plastic fuse box cover is missing on all my cars. In fact I
> >> have
> >>yet to SEE a cover in person in my years of VW and VW parts hunting. All
> >>have been thrown out by the owners or the people who are trusted with
> >>doing
> >>jobs on VWs. Sad.
> >>
> >> Bearing grease may be a better option as you say.
> >>
> >>Asad
> >>Karachi, Pakistan.
> >>
> >>
> >> >From: Chuck Kuecker <[EMAIL PROTECTED]>
> >> >Reply-To: Air-Cooled Volkswagen Discussion List
> >> ><[email protected]>
> >> >To: Air-Cooled Volkswagen Discussion List <[email protected]>
> >> >Subject: Re: [vintagvw] 68 bug Headlight problem
> >> >Date: Wed, 08 Aug 2007 06:24:21 -0500
> >> >
> >> >Hi, Asad,
> >> >
> >> >Good to hear that you found the trouble. If it was my car, I would
> >> >replace the loose #30 terminals with new ones to avoid future
>problems.
> >> >Those connectors work on pressure between the connector and blade to
> >> >make a "gas-tight" contact. If they get too loose, the contact will be
> >> >high resistance, and get hot.
> >> >
> >> >Petroleum jelly will evaporate too - just takes longer. If you have
>the
> >> >plastic cover over the fuses, they stay pretty clean. An alternative
>is
> >> >wheel bearing grease, but the jelly is neater and cleaner. You don't
> >> >have to use a lot of the stuff - just enough to make a film over the
> >> >part of the terminal where the contact is.
> >> >
> >> >Chuck Kuecker
> >> >
> >> >asad ishaque wrote:
> >> > > As a matter of fact day before yesterday in the evening I tinkered
>on
> >> > > my dub.....that was after I sent out the querries.....
> >> > >
> >> > > Had to get my bug on the road since I did not feel like
>borrowing
> >> > > dads ride for going to work that night.
> >> > >
> >> > > Had a spare brand new headlight relay left over from the resto
>of
> >> > > my second 68 bug.
> >> > >
> >> > > Simply replaced it and yes!! Everything picture perfect again!
> >> > >
> >> > > I found that four out of five, except for the number 30
>terminals
> >> > > can be rocked on the relay. Maybe this was causing probs. The
>spade
> >> > > connectors were all tight and snug, in fact so tight that I got the
> >> > > wire off instead of the connector while pulling one.
> >> > >
> >> > > The fuse box does hold the key to a lot of mysteries I have also
> >> > > learnt. I clean up the terminals with emery cloth like you say but
>go
> >> > > on to coat it with Phillips contact cleaner, which I have seen
> >> > > evaporated over a short while. Maybe petroleum jelly is a better
> >> > > option. But would it not create a mess by trapping dirt??
> >> > >
> >> > > Best regards,
> >> > >
> >> > > Asad
> >> > >
> >> > > Karachi, Pakistan.
> >> >
> >> >_______________________________________________
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> >>
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