Melting of the headlight switch isn't caused by installing more powerful headlights. Infact, the headlights are already on their own relays, for both low, and high beams. The problem has to do with the clearance lights. 10 seperate clearance & marker lights are powered thru that switch alone. Probably even more for those of us whom have modified our dash lights, as we removed a relay. The problem lies within the switch itself. It's only meant to carry the bare minimun load. Increase that load by way of resistance with dirty connections, and it's only a matter of time before the switch melts. I run 65W halogens, with 55W high beams, and have never had a problem with the fuse box, or relays. My switch was destroyed when a side marker light corroded, and the rust formed a bridge that bypassed the bulb, and grounded the wire directly. The lense cracked, and let water in, and the plastic conduit wouldn't let the water drain out. It's good that Houston is working to recreate the headlight switches. But it would have been even better to know about this happening. I never even knew that any sort of plans were in the works. Was this in a newsletter of some sort? -Robert vin 6585 "X" --- In dmcnews@xxxxxxxxxxxxxxx, "Video Bob" <videobob@xxxx> wrote: > I think it is great they are going to reproduce these switches, I only hope > that they build them better so they don't melt like the old ones do. > John Hervey came up with a fix for this by using a heavy duty relay to > bypass the switch. > So that when the switch is pressed, it activates the relay and turns the > lights on. > Not a bad idea and they are cheap too. > > Most of these problems that are caused by installing brighter halogen bulbs > that pull too much > juice and burn up the switch and fuse box. > > ...all that said, thanks to DMCH for making them. > - VB To address comments privately to the moderating team, please address: moderators@xxxxxxxxxxx For more info on the list, tech articles, cars for sale see www.dmcnews.com To search the archives or view files, log in at http://groups.yahoo.com/group/dmcnews Yahoo! Groups Links <*> To visit your group on the web, go to: http://groups.yahoo.com/group/dmcnews/ <*> To unsubscribe from this group, send an email to: dmcnews-unsubscribe@xxxxxxxxxxxxxxx <*> Your use of Yahoo! Groups is subject to: http://docs.yahoo.com/info/terms/