[DMCForum] Re: DMCH Reproduction headlight switch

["therealdmcvegas" <dmcvegas@xxxxxxx>]

--- In DMCForum@xxxxxxxxxxxxxxx, "Videobob Moseley" <videobob@xxxx> wrote:
> What was the minimum of switches they needed to make in order to
make them?
> - VB

The minimum order acccording to their website, is 1,000 switches. And
since they're asking for 250 pre-orders, that means that DMCH is
already ordering 750 of them on their own.

The headlight switch is a wearable part, both internally, and
externally. Aside from wearing out on the inside, it also can wear out
the graphic on the outside, if someone kept pushing on the center of
the button with their finger. And if you've ever seens a car that's
had the icon worn and scraped away, you know how nasty it looks.

Headlights themselves have absolutely nothing at all to do with the
headlamp switch. All it does, is feed power to two relays, which in
turn actually carry the load to the low, and high beams. However, the
headlight switch does carry the load for 10 external lights, and
anwhere from 6 to 11 internal lights. Let me break it down.

External:
4x Side Indicators
2x Front Markers
2x Rear Markers
2x License Plate Lights

Internal
5x Binnacle Lights
1x Cigarette Lighter
1x Shifter Indicator (if Automatic)
4x A/C Panel Lights (if dimmer bypass jumper installed)

Now that's a helluva lot of lights to try and power, just thru one
small switch. And you still have to remember that you've also got
several relays that are feed thru the switch as well. But, the switch
can do it, as many other cars out there do, as this is a common design
(so don't blame DMC!) But as soon as you get the slightest of shorts,
it will kill the switch.

Now the circuits here are fused, but only for the individual circuits,
and not for all of them together as a whole, to try and protect the
headlight switch itself (once again, a common design). Fusing the
switch isn't nessisarry, and could really be a hastle if some how, the
fuse did blow. Installing a relay is the key to protecting the switch,
by isolating the individual circuits, and letting the fuses continue
to do their job.

Otherwise, if you don't wish to modify the car, keep your sockets and
electrical connections clean, and switch over the lights to LEDs when
possible. You could safely swap the license plate lamps on the
outside, and ALL of the internal lamps on the inside. This alone would
greatly reduce the load on both the switch, and the wiring.

-Robert

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