The Stovebolt Site Forums The Shop Area The Electrical Bay Headlight issues.

Hi all. After 3 years of use, and a 2 year restoration, I now have headlamp problems. Low beams, great. High beams after a few minutes use, all 4 headlamps go off and on. It is the original harness. I have replaced headlamp switch, using two different aftermarket supliers, and dimmer switch. Checked all wiring/connectors for damage, and eliminated ammeter and ignition switch from power sources. Tapped power directly from battery. I changed grounds, and have checked voltage at all headlamp connectors. I have read in the searches of excess draw due to old wiring, replacement switches not having adequate thermo protection, and halogen bulb demands. I have the same lamps that were in it when purhcased 6 years ago, they burn very bright. I am now turning to the experts here. Please reply with your experiences. Does anyone have good referral for replacement wire harnesses without spending the ridiculous $500.00 price tag. I have also read about installing relays, but question why it would start now after all these years. Grant.

from the symptoms I would say it's weak bimetal breakers on the switch, but if you're satisfied the replacement is good, then it has to be something in the wiring that's causing excess current draw .... make sure all your grounds are good, the ones from the headlights on the core support particularly .... a relay shouldn't be needed if you have the correct wattage original type bulbs [50W]

a correct original style harness runs 200 at American Classic - and note at the left of the forum page, could be a good discount right now

Bill

I put a relay on my high beams in my 58. The factory wireing is not stout enough for all those lights. If you have Halegens they pull even more. I put relays on high & low on my 70. It increases the amount of light. The parts are cheap if you make it up yourself & you can buy a kit with everything including instructions for about $30

It sure sounds like the thermal breaker activating. When this is happening, if the breaker were interrrupting things, it would probably buzz and get very hot.

I replaced the light switch in my 59 with one from a vendor. The lights would stay on for 2 minutes or so and then blink off and on. Checked every ground on the truck an could find nothing wrong.Put a simple little relay in and no more problems.