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Remote headlight relays, floor dimmer, fuse box - diagram?
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70bus Premium Member
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PostPosted: Fri Nov 10, 2023 12:50 am    Post subject: Remote headlight relays, floor dimmer, fuse box - diagram? Reply with quote

While I am wiring the 65 up as stock to start, I will be converting it to run bigger bulbs run through remote relays; I have a Bus Depot kit with H4s and a relay harness. Being dumb, I of course want to go further, but I am not sure I can. Here's what I would like to do:
I've separated all three power feeds to the dash as advised by Bruce Amacker
Image may have been reduced in size. Click image to view fullscreen.


I have an extra, modern 'VW' fusebox with blade-type fuses, in the RHD fusebox position, and I ran a 10AWG wire straight from the battery to it; this will fuse the hi and low relay power to lights. If I did nothing else, it would look like this:
Image may have been reduced in size. Click image to view fullscreen.



However, that means cutting up the original harness, or taking it out and making a new one straight from the relays to headlights as shown, plus the park light wires... otherwise you'd have the unused wires hanging behind kick panels. I'm trying to be tidy.

An option is to just place the relays between the dimmer switch and the fusebox, that would look like this:
Image may have been reduced in size. Click image to view fullscreen.


but I'd really like to take all the high current off of the original fusebox.

Do I need the extra fuse through the original fusebox, or can I just jumper around it; i.e., use a connector similar to those used to connect turn signal switch. It adds a connection and resistance, but allows the stock wiring to be used. Would like like this

Image may have been reduced in size. Click image to view fullscreen.


I suppose I could use those same in-line connectors to extend the wires and use the blade-style box to fuse the lights after the relays if needed, but more complicated.

I really don't want to cut up a brand new headlight harness, nor pay more cash for a custom one made to eliminate these issues... but being cheap may be a bigger complication than it's worth?

Apologies if this is simple, or staring me in the face, but I've been turnining it over in my head all week and can't find a good answer on the web. A lot of thesamba relay pics feature a LOT of spaghetti, and I'm trying not to add to them.
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garym999
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Joined: November 26, 2022
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PostPosted: Fri Nov 10, 2023 10:13 am    Post subject: Re: Remote headlight relays, floor dimmer, fuse box - diagram? Reply with quote

I haven’t gone there yet but I am planning a change to a multi-way blade fuse box. I have the 3D prototype already printed. I know it moves away from stock but I consider it along the lines of front disc upgrades a safety feature.

If you are running H4s I’m not really sure you need any of this unless you are planning silly bulb wattages. In turn if that’s for better light coverage then LED should be considered, less current, brighter etc.

I have fused the main battery feed in the engine bay so ultimately the cab is fused at the highest level. Where you show one fuse per relay only one is needed for both as only one relay will be in use at a time.

The other wire I would consider fusing is the one back to the engine bay for the distributor, choke etc.

It looks like you are planning a new feed to the cab? If so make sure it is fused as close to the battery as you can. You are trying to protect the cable and prevent it catching fire.

If you are pulling a new feed and have a lesuire battery might worth pulling one from that too. Then you have the option to shed loads, radio, USB chargers etc.
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