Quality Wires for Headlights

Status
Not open for further replies.
M

moribundman

Joined
Jun 2, 2003
Messages
23,587
I am going to install new headlight wiring (with relays) and am not sure if the wires that I found are decent quality: 12 gauge Carol brand (E 1 8621-8). Vinyl insulation (I'm not going to spring for silicone!), the copper strands appear to be tinned. Is that good quality stuff?
 
Bear in mind that any vinyl insulation is not rated for use at temperatures exceeding about 160F. If exposed to those temperatures, it will become brittle and start cracking, leaving you with bare wire. Underhood temperatures in some cars can easily exceed 160F.

The correct insulation for underhood use is crosslinked polyethylene. This can be exposed to open flame and it doesn't get damaged. Look for type GXL primary wire. I believe you can get this at NAPA and other stores that sell to professionals. It probably won't be tinned, but then it doesn't need to be since the insulation won't break down--ever.
 
Hmm, so there's no crosslinked polyethylene insulated wire with tinned strands? I haven't held a thermometer under the hood, but I'm sure it's occasionally above 160 F. Silicone insulated wire is like $2 a foot. Ack!

PS: Yes, it's for the A4. The '96 doesn't use relays for low and high beam or fog light. The multifunctional switch tends to go bad (increasing resistance, heat, yada, yada, yada, you get the idea) and a new one is $150. That's why I want to add relays.
 
Alas, I'd like to use at least 4 colors to avoid confusion. 400 feet of wire is more than I need.
tongue.gif
I'll check NAPA and an electronic supply store.
 
Yeah, they have it all right. Even in all the pretty colors. Thanks for the link.

Should I go with the thicker (TXL) insulation, or is the thinner (SXL) one sufficient?
 
Mori, before you buy all the pieces check out this site

http://innovativewiring.com/

This guy has an excellent reputation in the GM B-body (Impala & Caprice RWD) and F-body (Camaro/Firebird) communities. The headlight relay harness he makes for the Caprice/Impala is similar to what you want. They have the same goofed up headlamp wiring as your A4. He does do custom work -- you may have to provide some measurements -- the quality is top notch and price is IMO reasonable.
 
I have all the necessary OEM and other electric connectors, relays, shrink tubing, soldering equipment (and skill) I need. The only things missing, and the most costly, are the wires.

PS: brianl703, thinner it is.
 
I use only ANCOR Marine Grade wiring for headlamps and other high demand uses. As well, their connectors (adhesive-filled) and shrink-tubing. The quality is unmatched by any automotive stuff.
 
Have you checked Painless Wiring? they have complete headlight kits with wire and relays. They're pretty reasonable, too. I bought a kit from them that keeps the lowbeams on with the high beams. Very nice quality.
 
Quote:

I use only ANCOR Marine Grade wiring

Click to expand...


Is that flame-resistant? I can hold a piece of GXL/SXL/TXL wire in a cigarette lighter flame for 10 seconds or more. After I wipe the soot off, you couldn't tell I did that.

I notice it is rated for 105C "dry" and 75C "wet".

GXL/SXL/TXL wire is rated for 125C, presumably "dry".

As far as their their crimp connectors, they look identical to the adhesive-filled connectors sold by Pep Boys/Autozone/etc. I don't see anything superior here. Not that I'd use such connectors for any wiring job I cared about since Weatherpacks are so readily available.

As far as the adhesive-lined heatshrink tubing, that is what Ford has specified for underhood useage for years. In fact I used some just yesterday that came with a replacement DPFE sensor. It came with a new plug and instructions to splice the new plug onto the old wiring. (Parts consolidation, apparently). They supplied three metal crimps and three pieced of adhesive lined tubing.

By the way, their waterproof fuseholder is a Delphi part or a copy of the original Delphi design.
 
Last edited:
The last car I did was one year ago. At that point I hadn't seen anything in the part stores that was comparable. OEM dealer parts may be.

Have you actually handled some of these, or are you going by online pics?

Using their 12-3 wire -- heavy in insulation and the wire is tin-coated -- is a bit of a bear as it is bulkier than comparable home wiring from HD.

One stop at the marine supply store does the job. I don't need to traipse around to three suppliers, and the quality is better.
 
Status
Not open for further replies.
Back
Top Bottom