84-85 High beam relay (FLAPS?)

[binger59]

Hello all,
I hope everyone is keeping busy (how can you not with a Vanagon) staying sane & safe. I'm currently running the SA headlight all the while running a relay setup. My high beams have become inoperable and turn off when selected. I think I've narrowed it to the relay. There were a couple of times that I wiggled the relay and lights went out. Any way I was wondering if there was a relay available at my local FLAPS that I could put in to get me by for the time being, $$ is a bit short at the moment. I scoured the archives and came up short. The current bulb setup is 60/55w. Any insight would be great. If I left anything out in the description I know you guys will be quick to correct me!! Thanks.

Scott
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Binger

1984 Westy
1986 7 Pass R.I.P. Donor van
2019 Jetta
2014 Passat
2019 Atlas
2006 Passat R.I.P.
1998 Jetta R.I.P.
1984 Vanagon R.I.P.

[Sodo]

Can you post a couple pics of the relay that you want to replace?
One pic of the terminals end.

A relay should cost $5 or less, and there is no doubt your local FLAPS has them.
The little cube relays, often called "Bosch Relays" can switch 30 amps. Your headlights being appx 60watts (x2 = 120 watts) require up to 10 amps. So the 30A Bosch type relay is great for what you want to do.

If it's plugging into your fusebox it might be a little more difficult, but let's start with a pic.

If you can get crazyvwvanman's attn, I'm sure you will get a better answer.
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'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb

[binger59]

I have to add that that I’m running the inner beams for the SA as well.

_________________
Binger

1984 Westy
1986 7 Pass R.I.P. Donor van
2019 Jetta
2014 Passat
2019 Atlas
2006 Passat R.I.P.
1998 Jetta R.I.P.
1984 Vanagon R.I.P.

[hardway]

The relay in that photo has melted the housing at the output leg (87). Either the load is really high or there was a bad connection there that became a heater.

Any 4 or 5 prong power relay with the same terminal designations will work.

[binger59]

There was some melt that happened. I was running 90/100 for a very brief period. I went over all the connections today. Everything looks good on the high and low wiring.
_________________
Binger

1984 Westy
1986 7 Pass R.I.P. Donor van
2019 Jetta
2014 Passat
2019 Atlas
2006 Passat R.I.P.
1998 Jetta R.I.P.
1984 Vanagon R.I.P.

[nemobuscaptain]

Any flaps will have that.
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Ohio Valley Tribe, Full Moon Bus Club https://www.facebook.com/groups/294422277314227/

https://www.facebook.com/groups/FullMoonBusClub

RIP Bob Hoover https://www.thesamba.com/vw/forum/viewtopic.php?t=427791
Hoover Sermons: https://www.vwsage.com/images/vwsage/Bob%20Hoovers%20Sermons.pdf

[binger59]

Thanks for help everybody.
_________________
Binger

1984 Westy
1986 7 Pass R.I.P. Donor van
2019 Jetta
2014 Passat
2019 Atlas
2006 Passat R.I.P.
1998 Jetta R.I.P.
1984 Vanagon R.I.P.

[Sodo]

If it runs high beam as all four lights. 90+90+100+100= 380w = 27-30Amps then that relay was running at it's maximum.
Don't wanna run it at max, because the wires are OLD.

To run 90/100 you probably should have the system re-wired to use two relays, one for left, and one for right.
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'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb