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Headlight Selector Switch Melting


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#31 dklawson


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Posted 26 February 2016 - 12:55 PM

When adding relays, make VERY sure that failure of any ONE relay will not take out both headlights, otherwise you are seriously increasing the risk of a crash due to losing both headlights simultaneously in the dark. That goes for fuses too. Relays are usually cheap, nasty things, which like everything else electrical can fail suddenly.



Tiger, you have posted this several times in the past.  


Safety is great and I am not discouraging anyone from building the safest solution they can.  However, consider for a moment that in most factory wiring schemes the headlights are not fused at all and that one switch contact supplies both high beams and another switch contact supplies both low beams.  Using a single relay for high and a single relay for low is not inherently different than the factory wiring.  The fuses represent an increase in wiring safety no matter how many are fitted.


Perhaps your phrase "ONE relay will not take out both headlights "  is meant to suggest using ONE relay for BOTH high and low beams.  That would be dangerous.  However, all the schematics you find online and all the kits you find for sale will have at least two relays.  I have never seen anyone (or any kit) where only one relay is used.  

Edited by dklawson, 26 February 2016 - 01:05 PM.

#32 WiredbyWilson



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Posted 26 February 2016 - 01:16 PM

The kit we build is a "non-total failure kit", thus each beam is relayed and each headlight is fused (2 relays and four fuses). The is tailor made for a mini and takes around an hour to fit - with no cutting of the original wiring - simple plug and play!


£60 plus postage and with full support via instant messenger.


Yes there are kits on ebay, so there is no hard sell from me. BUT our kit uses the original colour coded wiring (simple fault finding) and correct terminals, along with every joint being crimped, solderd and then adhesively heatshrunk. The kit is designed to last the lifetime of the car - as well as being removabel to your next mini should you choose to.


Give us a shout if you're interested.



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