Re: Possible culprits behind intermittent headlight loss?

Doc wrote:
> Have a '66 Fairlane wagon, the headlights will blank out after maybe
> 15 - 20 minutes on low beam. Turning the switch off for a few secs and
> then turning on will typically get them back on tem****arily but
> they'll continue to go out. Further, hitting the hi beams is almost
> guaranteed to kill the lights. Replaced the switch and the floor
> dimmer, neither cures the problem.
> 
> Any suggestions as to where to begin looking?
> 
> Thanks.
> 

I see that happen to old vehicle when folks try to run halogen bulbs in 
them without adding a power relay.

The bimetal circuit breakers in the old switches cannot take the amp 
draw the modern halogen bulbs draw.

The old time conversion kits that were sold when halogens first came out 
are a simple Bosch relay that is fused to the battery and wired so the 
switch is just the trigger for the relay.

Here is a site on how to wire one in.
http://www.classictruckshop.com/clubs/earlyburbs/projects/bosch/relay.htm

The other reason I see the breaker cook is a bad connection in the plug 
for the headlight switch.  The main power wire's spade connector can get 
ratty which will cause arcs and heat and breaker failure.

I see this same bad connection on the floor dimmer switch plugs.

And last, a bad ground can cause heat issues.  I would verify the 
headlight ground tags and the body's main ground from the battery.

Mike
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