Headlight plugs melted

[BigRed76]

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 After inspecting it I found that the headlight bulb itself melted enough to cause the low beam terminal on the bulb to come apart. Since the connector is ceramic it was unharmed, but the plastic sheath around the ceramic did melt a little too. What is the deal here? Am I just not supposed to be running 100W bulbs?

[skorpioskorpio]

High wattage low beams are tricky just not enough air movement to cool the housing at low speeds or worse stopped. If you fried one of the bulbs, now may be the time to consider a little more sane 55/100 if you want the brighter high beams. I don't think you ever mentioned the manufacture of the H4 capsule but safe recommendations are Osram (DE), Philips (DE), Narva (DE) and Norma (FR) and avoid the "super blue" or Xenon types, they run hotter and although may seem brighter (mostly because the color triggers your eyes into thinking it's daytime because it over sensitizes the blue cones in your retina, which is bad BTW, it creates night blindness in any other direction and to oncoming drivers, and pretty much obviates object definition, hence the reason why quality sunglasses block this color wavelength, anyway another discussion). I have Narva, Philips and Norma H4s and don't think there is any plastic in them at all, though I don't have them in hand at the moment to say that with 100% certainty.

For the record I have run 55/100s before without issue, and the light I have ready for my Jimmy project have 100s in everything but low beams and fogs, I also picked up a set of 5 3/4" high/low outers (which may be RHD UK/Aus/Japan housings) if they turn out to be LHD I will run 55/60 H4s in them and 55 watt highs, if I run the low only outers I'll run 100W highs. Then again I'll have 2 driving lights and 2 pencil beams on the front as well in 8" reflectors, all running 100 watters, enough to throw about a mile and a half, so it's all relative I guess.

[MARKDTN]

I would look at grounds again. You may not have a really good ground on that side.

[BigRed76]

Well the only reason I went with the 100W bulbs was for brightness, and they are Hella xenon bulbs, same brand as the headight housings. My ultimate goal is bright headlights, so are there ways to get brighter bulbs without higher wattage?

[DGulliver]

I installed the Sylvania "Silverstar Ultra" headlamps in my '72, they are easily far brighter than my old standard off the shelf halogens were. (Stock wiring so far, but I do intend to upgrade all of that too, with another project.)

I subsequently put them in my Denali, and my Mercedes SLK, it was night and day difference (no pun intended). It's really amazing how bright they are, and what a difference there is at night. I didn't realize that halogens "fade" over time..

[Stocker]

Originally Posted by BigRed76

My ultimate goal is bright headlights, so are there ways to get brighter bulbs without higher wattage?

Not really, other than ensuring full voltage & current with relays, which you have already done.

Interesting material: http://www.danielsternlighting.com/t...uperwhite.html

[boynton]

I would assume you have a ground problem. I would clean everything end make sure those connections are good.