Right. I thought I'd resurect (sp?) this thread as its on topic.
I've been having problems with the Sisley and it's headlight switch. Burnt out two Fiat ones, and so install a Heavy Duty general one from Halfords which has finally burnt out. So thought as more of a bodge I'd wire them in direct by putting a bit of wire between the two connections.
Worked fine for another week until sitting in traffic and I see's smoke in front of me
So I thought right, enough is enough, and finally (was planning on doing it eventually) got around to cleaning the earth hedgehogs and replacing all of the female earth connectors on the inside of both wings.
Went out that night, but that hadn't helped
So the next step - relaying the headlight individually to releave all strain from origional wiring.
Used some nice minature relays aquired from mk2+3 Punto's in a few scrappys and wired them in one afternoon last week.
Minature relay
You can see that I even got my fingers dirty
All was good. Driving around Norwich and the bit of wire that I'd bodged in that was over heating and melting was staying nice and cool (and I swear the headlights were brighter!)
Then I left Norwich for the dark country roads where I started to use the main beam. Touched the bodged bit of wire again...Only to burn my fingers
Main beam is now causing the system to over heat. So now got to relay each headlight for the main beams. But atleast the problem will be solved finally, even if I do have 2 relays by each headlight. But atleast the minature relays look neat and if my 'touch the wire and seek heat' test go well I'll be able to install a propper switch again
The only downside is that there is no-longer the dim-dip function due to the way I've wired the relays in. So it's with dipped headlights or nothing. Don't think this is an MOT failure though as the parking lights through the ignition still work fine.
Some pic's of the finished job though
I seem to have collected alot of fused spurs with all the lights I've had / got on the Sisley.
Nearside headlamp and minature relay. +ve wire was run along the bulkhead and down the leg from the battery for this relay and then
-ve just across to hedgehog.
Look how nice and clean my earths and hedgehogs are now also, hehe.
Offside headlamp and minature relay. +ve wire run down leg from battery. Then -ve back to earthing block half way up leg.
You can also compare the minature relay in size to the full sized 40 amp one installed for the grille lights in the top left of the pic.
Jon.
P.s, I recomend you try and aquire some of these minature relays if in a scrappy with Punto's, as they seem to come in handy
