IML: Protecting the Expensive Rocker Type Headlamp Switch

["Eric" <gearhead@xxxxxxxxxxx>]

Bob,
I understand those switches are hard to find / expensive. I'm finding some 
benefit with crimping down the female connectors at my high power drawing 
plug-on connectors. After 30 years of being heated and cooled with general 
usage and with the vibrations accompanied with driving, the metal female 
connector ends have a tendency to open up. When they do this, they lose an 
effective consistant tight connection which builds heat. I take the metal 
pick in my Leatherman's pocket knife and use it to lift the holding tang on 
the connector to release it from the plastic plug housing. With the 
connector out of its plastic holder, I can then do a clean up of the 
connector and crimp down the rolled sides to make a tighter fit to it's male 
counterpart.

Putting a relay in the headlamp circuit would be the preferred way to extend 
the life of these switches. An excellent site for this upgrade is 
http://www.danielsternlighting.com/tech/relays/relays.html
Dan also supply's the needed equipment under the "Products" part of his 
website, http://www.danielsternlighting.com/products/products.html
The effect of this upgrade is to reroute the 100+/- watts that would 
normally run through the headlamp switch and send it through a relay 
instead. The end effect is that you are only running the small amount of 
power that the relay uses through the headlamp switch.

I've replied with this info a number of times for you hot-headlamp-switch 
syndrome Haze Green Era folks, has anyone made the upgrade with the result 
of a less hot headlamp rocker switch? With the cost of these switches, the 
relayed circuit upgrade would be a cost effective (ask Dan if he still 
offer's his MOPARite discount, he's mopar sympathetic) preventative 
maintenance procedure. $45-55 for the relay plus a couple bucks in wiring 
and connectors vs $100 for a NOS switch just makes $ense. The installation 
is very easy, I installed one in my '72 Newport and only had to putz around 
the front of the engine compartment to mount the relay and do the necessary 
wiring from the alternator and headlamps.

Eric
Portland, Oregon


From: "BOBSMOPAR" <bobsmopar@xxxxxxxxxxxxxx>
Subject: IML: 68 head lights
Date: Thu, 23 Sep 2004 17:45:15 -0400
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Hi all.
How hot should my head light switch get when using my lights.
Here is what I done to the car I have installed a new head light switch =
that I bought from car quest it is wired right D>2 told me how to wire =
it.
And it has worked great until now.
When I stop at a red light or just stop my voltage gauge drops below the =
center of the gauge and when I step on the gas to move it goes back to =
charging the battery.
Last night I blew a fuse that is on the back side of the switch and the =
switch was really hot.
Were would be the best place to look to fix this problem or does the =
switch get this hot just from the amount of voltage that goes thru it.
Thank you for any help that you can give me.
Bob
68 Imperial convertible



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