devildog

I am replacing the rusted-out headlight cans on the 61. I might as well install relays to avoid headlight power going thru dash switch. I think I can scratch out the circuits; however, if one of you many smart people on the forum has a headlight relay conversion circuit, please post or send.

many thanks

Joe

Frankie the Fink

427390HP

Here is a thread discussing relays in a C1:
https://www.corvetteforum.com/forums...g-diagram.html

Here are two links to MAD Electrical pertaining to relays:

http://www.madelectrical.com/electri...adlights.shtml
http://www.madelectrical.com/catalog/rly-1.shtml

I pieced together my own kit when I put relays in my '60, but it may be easier to just get the kit from MAD.

Here are two simple but good diagrams. One is for a 2 headlight system and the next is for a 4 headlight system. I showed the two headlight system diagram because it show how to connect through the dimmer switch.

Terry

Frankie the Fink

That is almost exactly how I wired my 61 headlight relays - I mounted the relays in the splash pan area under the windshield washer fluid reservoir - you almost have to do a headstand to see them. I powered them off the horn relay buss though and not directly from the battery IIRC. If you're clever with connector terminals and a crimping tool you don't have to butcher up the original harness either (I didn't)...

AZDoug

I made a relay harness, that zip tied to the front panel supports (you can't see it unless you use a mirror or take the grill out and stick your head in there), and it plugs into the factory connectors---the headlight harness on one end, the individual headlight pigtails on the otehr, so there was no harness cutting, it is easily removable.

I also added a separate 10 ga ground wire to frame as well as the new 10 ga power wire to the relays.
Doug

devildog

Thanks to all of you. John 'Plasticman' sent me his schematic which was great. I have the relays installed and the improved brightness is unbelievable. I have had aircraft landing lights in the inboard high beams for about 20 years...no driving out of the headlight's light. Now I can use them without fear of torching the under dash electrical system.

Pretty easy job, a must do on a C1 that is driven.

Joe

K2

Or you can install single relay to feed B+ power to dimmer switch and triggered by headlight switch. Simpler and cheaper..

Frankie the Fink

Mad Electric has the specifics on their testing but even a minuscule drop in voltage at the headlights can cause a double digit percentage drop in headlight brightness. Relays are a big help. The repro headlight dash switch thermal cutouts are crappy too so taking the load of the dash switch is an added benefit...