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#1 |
Registered User
Join Date: Jan 2010
Location: Loveland, CO
Posts: 1,921
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Headlight plugs melted
Last summer I upgraded my headlights with Hella headlight housings and 100W/80W H4 bulbs, and wired relays into the headlight harness for low beams and high beams. Fast forward a year later and my passenger headlight is out because the headlight connector has melted, bad. After looking at the driver side I noticed it's melted too. Are there any connectors I can used as a replacement that won't melt again? or is this just a consequence of too much current flow to my headlights?
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Zach 1970 Chevrolet Custom Camper K20 1971 GMC Super K2500, 12V/NV4500 swap in progress 1971 Chevrolet Custom C10 1972 Chevrolet Custom Deluxe C20, 5.3/4L60E 1972 Oldsmobile Cutlass Supreme, 455/TH400, 3.73 posi 2004 GMC Sierra 2500HD, LB7/Allison, CCSB 2005 GMC Sierra 1500, 5.3/4L60E, CCSB |
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#2 |
Registered User
![]() Join Date: Mar 2012
Location: Okanagan Valley, BC, Canada
Posts: 1,237
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Re: Headlight plugs melted
The headlight connector is melted at the back of the headlight? That's odd with a relay harness. Did you make the harness yourself? What gauge wire did you use? Did you just wire relays into the existing headlight wiring or did you make an entire new harness? The factory headlight plugs can't handle that kind of power so you need to make a whole new harness that takes power direct from the battery to the headlights and use your factory headlight plugs as the trigger for the relays. LMC sells these harnesses.
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#teamlongbed "I refuse to go disc brakes. I actually love drum brakes. It makes for an adventure." - 50bomb 1978 Chevy shop truck - static 6/8" 1970 GMC 1500 - Accuair eLevel Resto-mod http://67-72chevytrucks.com/vboard/s...d.php?t=537497 |
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#3 |
Registered User
![]() Join Date: Mar 2012
Location: Okanagan Valley, BC, Canada
Posts: 1,237
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Re: Headlight plugs melted
Posted via Mobile Device
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#teamlongbed "I refuse to go disc brakes. I actually love drum brakes. It makes for an adventure." - 50bomb 1978 Chevy shop truck - static 6/8" 1970 GMC 1500 - Accuair eLevel Resto-mod http://67-72chevytrucks.com/vboard/s...d.php?t=537497 |
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#4 |
Registered User
![]() Join Date: Mar 2013
Location: Clayton, Ca.
Posts: 162
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Re: Headlight plugs melted
check this listing I just bought on ebay 140984076348. But I agree if you upgraded your wiring with thicker gauge wire and added relays you shouldn't have a problem. I use 12 gauge. The problem with doing it yourself is the pigtails you can buy to make your own harness come with such small gauge wire you really need to start out with the bare connectors so you can start with 12 gauge right at the terminal.
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#5 |
Senior Member
Join Date: Jan 2003
Location: daytonabeach
Posts: 22,956
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Re: Headlight plugs melted
clean tight connections and establishing a great groound path for electricity to flow aare good for better operation and less heat
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71c-10 350/2004r/4:11 lowered3/4 longbed/dead by hurricane MEANING OF DEATH::::: SOMEBODY ELSE GETS YOUR STUFF DONT BELIEVE EVERYTHING YOU THINK TAKE MY ADVISE;I DON'T USE IT ANYWAY |
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#6 |
Registered User
Join Date: Mar 2013
Location: Clifton, Maine
Posts: 86
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Re: Headlight plugs melted
Do they run that hot temperature wise. It almost sounds like a high heat issue from the bulb rather than a current flow issue. What size fuse are you running? I would think the fuse would blow before you start melting wires. Keep us posted, I was going to install these headlights in mine. I want to know all about these things now!
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#7 |
Registered User
Join Date: Jan 2010
Location: Loveland, CO
Posts: 1,921
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Re: Headlight plugs melted
Yes I wired relays into my factory harness. The relays are powered from the battery with a 12 gauge wire with a 20 amp fuse. And yes it's the connectors on the headlights themselves that are melted, but the wires are fine, none melted. I haven't double checked the grounds yet. I assumed it wasn't just heat from the bulbs causing it since each headlight has a rubber boot on the back and both of them are fine. It seems that the only weak point with wiring relays into the factory harness is the connectors.
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__________________
Zach 1970 Chevrolet Custom Camper K20 1971 GMC Super K2500, 12V/NV4500 swap in progress 1971 Chevrolet Custom C10 1972 Chevrolet Custom Deluxe C20, 5.3/4L60E 1972 Oldsmobile Cutlass Supreme, 455/TH400, 3.73 posi 2004 GMC Sierra 2500HD, LB7/Allison, CCSB 2005 GMC Sierra 1500, 5.3/4L60E, CCSB |
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#8 |
20' Daredevil (Ret)
![]() Join Date: May 2003
Location: Jefferson State
Posts: 13,647
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Re: Headlight plugs melted
The OEM headlamp wiring including switch is not designed to handle the current draw of your overwattage bulbs (which we all know, hence the relay upgrade), so maybe the connectors aren't up to the task either. Try something like these NAPA connectors: http://www.napaonline.com/Catalog/Ca...479_0334573974
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- Mike - 1972 K20 LWB 350/350/205 RIP El Jay |
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#9 |
Registered User
![]() Join Date: Mar 2013
Location: Clayton, Ca.
Posts: 162
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Re: Headlight plugs melted
did you look at the item number on EBAY 140984076348 ? I would paste it but I dont know how.
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#10 |
Registered User
Join Date: Jan 2010
Location: Loveland, CO
Posts: 1,921
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Re: Headlight plugs melted
I would think the napa connectors are just an oem replacement, and would probably melt again. But I did just do a search on eBay for h4 connectors and I like the sounds of the ceramic connectors, that might be what I need.
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__________________
Zach 1970 Chevrolet Custom Camper K20 1971 GMC Super K2500, 12V/NV4500 swap in progress 1971 Chevrolet Custom C10 1972 Chevrolet Custom Deluxe C20, 5.3/4L60E 1972 Oldsmobile Cutlass Supreme, 455/TH400, 3.73 posi 2004 GMC Sierra 2500HD, LB7/Allison, CCSB 2005 GMC Sierra 1500, 5.3/4L60E, CCSB |
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#11 |
Registered User
Join Date: Jan 2010
Location: Loveland, CO
Posts: 1,921
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Re: Headlight plugs melted
I think I'm going to order a pair of these, anyone see a reason they won't fix my problem?
http://www.ebay.com/itm/Ceramic-Auto...74016a&vxp=mtr
__________________
Zach 1970 Chevrolet Custom Camper K20 1971 GMC Super K2500, 12V/NV4500 swap in progress 1971 Chevrolet Custom C10 1972 Chevrolet Custom Deluxe C20, 5.3/4L60E 1972 Oldsmobile Cutlass Supreme, 455/TH400, 3.73 posi 2004 GMC Sierra 2500HD, LB7/Allison, CCSB 2005 GMC Sierra 1500, 5.3/4L60E, CCSB |
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#12 | |
Registered User
Join Date: Mar 2013
Location: Marquette michigan
Posts: 828
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Re: Headlight plugs melted
Quote:
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#13 |
Registered User
Join Date: Nov 2010
Location: Los Angeles, CA
Posts: 1,018
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Re: Headlight plugs melted
80-100 is a hot bulb, I'd use a ceramic connector if I were you, now if I were me, which I am, I'd also look for unassembled ceramics and use a high heat wire to the relay. It's not the high beam that is the problem it's using that hot of a low beam. Also make sure when you did your relays you didn't wire it to keep the low filament on when the highs go on, they should be *or* not *and*, the reflector will not handle 180 watts of halogen heat, no reflector can dissipate that much heat, even the best of the European reflectors. So which Hellas did you get convex or flat?
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#14 | |
Registered User
Join Date: Jan 2010
Location: Loveland, CO
Posts: 1,921
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Re: Headlight plugs melted
Quote:
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__________________
Zach 1970 Chevrolet Custom Camper K20 1971 GMC Super K2500, 12V/NV4500 swap in progress 1971 Chevrolet Custom C10 1972 Chevrolet Custom Deluxe C20, 5.3/4L60E 1972 Oldsmobile Cutlass Supreme, 455/TH400, 3.73 posi 2004 GMC Sierra 2500HD, LB7/Allison, CCSB 2005 GMC Sierra 1500, 5.3/4L60E, CCSB |
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#15 |
Registered User
Join Date: Nov 2010
Location: Los Angeles, CA
Posts: 1,018
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Re: Headlight plugs melted
Don't need the part number, I just got a full set of Marchal quads for my Jimmy project, was just curious, though I'd love to see pics of the flats on your truck. The Marchals I got are the dedicated meeting (lows) outer, main (Highs) inner lights, so no 2nd filament in the outers.
And no the factory wiring would use the shielded filament for lows and the open filament for high and on an E2 Hella it should be a completely different beam when you go from meeting to main with one focused flat with a ramp up the right side and the latter focused into a long range beam. |
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#16 |
Senior Member
![]() Join Date: Feb 2001
Location: New Madison, Ohio
Posts: 21,365
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Re: Headlight plugs melted
I am glad it didn't cause more issues.
Keep us updated
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A husband can be right...or...A husband can be happy. ![]() 67-72 Chevy and GMC Trucks...The Classic Truck for the Classic Folk. ![]() 1970 CST Two tone green, 402BB, 400 Automatic, Tach, Buckets, AC, AM-FM, Tilt, GM CB, GM 8 Tract, LWB, etc ![]() ![]() JOHN 17:3...The better side of "LIFE" Remember: Everyday is a good day...Some are just gooder! |
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#17 |
20' Daredevil (Ret)
![]() Join Date: May 2003
Location: Jefferson State
Posts: 13,647
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Re: Headlight plugs melted
Interesting, I didn't know they were still available. Do you mind saying where you bought them? I had a pair of 7" Marchals back in the day, very nice lamps. Sorry about the thread hijack but others may be interested also.
__________________
- Mike - 1972 K20 LWB 350/350/205 RIP El Jay |
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#18 | |
Registered User
Join Date: Jan 2010
Location: Loveland, CO
Posts: 1,921
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Re: Headlight plugs melted
Quote:
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__________________
Zach 1970 Chevrolet Custom Camper K20 1971 GMC Super K2500, 12V/NV4500 swap in progress 1971 Chevrolet Custom C10 1972 Chevrolet Custom Deluxe C20, 5.3/4L60E 1972 Oldsmobile Cutlass Supreme, 455/TH400, 3.73 posi 2004 GMC Sierra 2500HD, LB7/Allison, CCSB 2005 GMC Sierra 1500, 5.3/4L60E, CCSB |
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#19 |
Registered User
Join Date: Jan 2010
Location: Loveland, CO
Posts: 1,921
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Re: Headlight plugs melted
Ordered a pair of ceramic connectors today, so hopefully they will take the heat.
__________________
Zach 1970 Chevrolet Custom Camper K20 1971 GMC Super K2500, 12V/NV4500 swap in progress 1971 Chevrolet Custom C10 1972 Chevrolet Custom Deluxe C20, 5.3/4L60E 1972 Oldsmobile Cutlass Supreme, 455/TH400, 3.73 posi 2004 GMC Sierra 2500HD, LB7/Allison, CCSB 2005 GMC Sierra 1500, 5.3/4L60E, CCSB |
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#20 | |
Registered User
Join Date: Jul 2012
Location: United States
Posts: 268
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Re: Headlight plugs melted
Quote:
Hopefully the terminal is high quality and the wire decent gauge. Everybody is getting cheap and skimping on quality and copper.
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86' C30 Dually Crew Cab Ranch truck, carb'd 454, TH400, towing a slant load 4 horse trailer. |
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#21 |
Registered User
Join Date: Jan 2010
Location: Loveland, CO
Posts: 1,921
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Re: Headlight plugs melted
Yeah depending on how the terminals look when I get them I may just get some OEM terminals and crimp them onto my existing wires.
__________________
Zach 1970 Chevrolet Custom Camper K20 1971 GMC Super K2500, 12V/NV4500 swap in progress 1971 Chevrolet Custom C10 1972 Chevrolet Custom Deluxe C20, 5.3/4L60E 1972 Oldsmobile Cutlass Supreme, 455/TH400, 3.73 posi 2004 GMC Sierra 2500HD, LB7/Allison, CCSB 2005 GMC Sierra 1500, 5.3/4L60E, CCSB |
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#22 |
Registered User
![]() Join Date: Mar 2013
Location: Clayton, Ca.
Posts: 162
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Re: Headlight plugs melted
I bought bare terminals from the same place I got the heat resistant plugs from. They say they will take 12 gauge wires. By the way don't try typical female spade type terminals you see at the hardware store. Not only will they not stay put in the plug ends but even if you ditched the plug ends and decided to hook them up as 3 individual connectors, they are not wide enough to fit onto the spade of the headlight.
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#23 | |
Registered User
Join Date: Jan 2010
Location: Loveland, CO
Posts: 1,921
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Re: Headlight plugs melted
Quote:
__________________
Zach 1970 Chevrolet Custom Camper K20 1971 GMC Super K2500, 12V/NV4500 swap in progress 1971 Chevrolet Custom C10 1972 Chevrolet Custom Deluxe C20, 5.3/4L60E 1972 Oldsmobile Cutlass Supreme, 455/TH400, 3.73 posi 2004 GMC Sierra 2500HD, LB7/Allison, CCSB 2005 GMC Sierra 1500, 5.3/4L60E, CCSB |
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#24 |
Registered User
![]() Join Date: Mar 2013
Location: Clayton, Ca.
Posts: 162
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Re: Headlight plugs melted
I here ya. If I had seen the ones you found first, I would have done the same. At the time I was only looking for the terminal ends, and I added the plugs as a second thought just to make the shipping more sensible.
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#25 |
Registered User
Join Date: Jan 2010
Location: Loveland, CO
Posts: 1,921
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Re: Headlight plugs melted
So a little update on this, I installed the ceramic headlight bulb connectors with a new pair of the same headlight bulbs I was running. Now 3 months later my passenger headlight is out again
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__________________
Zach 1970 Chevrolet Custom Camper K20 1971 GMC Super K2500, 12V/NV4500 swap in progress 1971 Chevrolet Custom C10 1972 Chevrolet Custom Deluxe C20, 5.3/4L60E 1972 Oldsmobile Cutlass Supreme, 455/TH400, 3.73 posi 2004 GMC Sierra 2500HD, LB7/Allison, CCSB 2005 GMC Sierra 1500, 5.3/4L60E, CCSB |
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