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Anatomy of an over the top headlight setup.

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 Post subject: Anatomy of an over the top headlight setup.
PostPosted: Mon Mar 28, 2011 4:18 pm 
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I sprinkle rubber on my Cherios
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Specs:

Hella Housings
55w/100w H4's
130w H1's
5 relay block (one for lows, individual relays for each high)
6ga lead from battery to pre-relay distribution block

I'm converting my 1989 200tq to an early Type 44 5000 quad light setup. It is ugly, yes. I did it mostly because I wanted as much wattage up front as possible without aux. (think "rally") lights, and going this route is far cheaper than sourcing Type 44 euro lights (which only use one H4).

I'll be using this as my mini-project thread with pictures when I finally get around to doing the swap.

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1989 200tq 192whp/247tq @14psi on CIS w/stock 10vt IC, stock turbo---*sold*
1989 200tq Avant K26/T04E 50 trim/AWIC/034 SIC...still CIS
1990 Audi 90 FWD ABZ tire melter.....in progress


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 Post subject: Re: Anatomy of an over the top headlight setup.
PostPosted: Thu Mar 31, 2011 12:00 pm 
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mach 2 with my hair on fire
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I've got a similar setup on my urq. Works *very* well!

In all reality, with 4 lamp rectangular conversions (especially with higher power bulbs), I think you get *better* lighting that going with the euro setup..

A suggstion: Feed from the alternator, not the battery.
WHy? When the motor is running, elctricity for any loads is *supplied* by the alternator
(but yes, *stored* by the battery. In a 'steady state' situation, battery does nothing)
Alternator is the net supplier of power, so why have the power go from the alternator, to the battery (via stock wiring), *then* to the headlight relays?

Cut out the middleman, and go straight to the alternator..
Also consder two feeds from the alternator of smaller gauge wire (At least for the first bit, then splice to your heavier wire), as they will be more flexible and not put as much stress on the alternator lug (you can then use two lugs)

(I had the lug feeding all my car except the headlights, break off from the alternator by fatigue bending cause by stiff feeder wire at the lug) Headlighs had full power, but rest of car was running on battery. Did you know a MAC 11 will still (sort of) run at 8 volts? Was getting backfires and such, but still kind of ran!)

Also consider fusing each load separately, (as factory) so one failure won't leave you in the dark... :D

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91 20vt Avant (The Couch Rocket...So fast in such comfort..)
83 URq ("Roland" Think: 'The Gunslinger'.. Just gets the job done.. )
85 4kq ("Rusty", because he is. Best winter car *ever*!)


(Plenty Many Audi Pictures: http://www.frankdekat.com/pics/audi/Audipics.html )


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 Post subject: Re: Anatomy of an over the top headlight setup.
PostPosted: Thu Mar 31, 2011 1:45 pm 
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If you do that wouldn't you be guaranteed to not have any headlights if you throw an alternator belt?

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 Post subject: Re: Anatomy of an over the top headlight setup.
PostPosted: Thu Mar 31, 2011 1:52 pm 
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I haven't fully built the harness yet, so I'll do that instead of the battery.

The relays are fused indivdually, yes.

As for chucking a belt and losing lights: that is false. The battery will still supply power to the post on the back of the alternator, just not very much for very long.

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1989 200tq 192whp/247tq @14psi on CIS w/stock 10vt IC, stock turbo---*sold*
1989 200tq Avant K26/T04E 50 trim/AWIC/034 SIC...still CIS
1990 Audi 90 FWD ABZ tire melter.....in progress


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 Post subject: Re: Anatomy of an over the top headlight setup.
PostPosted: Thu Mar 31, 2011 5:08 pm 
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mach 2 with my hair on fire
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pitts wrote:
If you do that wouldn't you be guaranteed to not have any headlights if you throw an alternator belt?


Nooo... The wiring between the battery and the alternator is a 2 way street. If you dropped a belt, power would still go from the battery to the (non running) alternator power lug, then to the lights.

Really though.. How long you think the battery will hold up, running all 460 watts of 'daylight' out the front of the car? :-)

(FYI: If you run high power bulbs in the winter, you *can* crack a lens if it gets a quick thermal shock, like a spray of slush from an oncoming car.. :frustrated:

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-=Frank=-

Image <- "The Twins" Image

91 20vt Avant (The Couch Rocket...So fast in such comfort..)
83 URq ("Roland" Think: 'The Gunslinger'.. Just gets the job done.. )
85 4kq ("Rusty", because he is. Best winter car *ever*!)


(Plenty Many Audi Pictures: http://www.frankdekat.com/pics/audi/Audipics.html )


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 Post subject: Re: Anatomy of an over the top headlight setup.
PostPosted: Thu Mar 31, 2011 5:41 pm 
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mach 2 with my hair on fire
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Katman wrote:
(FYI: If you run high power bulbs in the winter, you *can* crack a lens if it gets a quick thermal shock, like a spray of slush from an oncoming car.. :frustrated:


There's an easy solution to that if you want to get creative...... make a plastic cover for the headlights. Might not be pretty, but it could be functional.

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 Post subject: Re: Anatomy of an over the top headlight setup.
PostPosted: Thu Mar 31, 2011 5:45 pm 
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But would they melt?

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 Post subject: Re: Anatomy of an over the top headlight setup.
PostPosted: Thu Mar 31, 2011 5:55 pm 
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Location: Sobbing in the corner.....
why wouldnt you get some other t44 turbo aero housings and modify them?

the glass is only bonded on with some sort of cheap epoxy stuff. some heating and careful work would remove the glass.

you can then make a mold of said glass in any cheap molding compound you can think of, make a replacement lens, hollow out the reflectors and mount elipsoid HID lamps inside?

yes it is alot more work, but the end result is a FAR superior setup in terms of looks, functionality, lumen output, ect.

i completely understand the quick and dirty quad setup and it works very well, but in my opinion the looks are horrible.

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Audi, imprisoning me, all that i see, absolute horror. I cannot live, i cannot die, trapped in my audi, my audi my holding cell..

1988 Audi 5ktq - 10vt Ms&s Extra <- sold then someone killed it.
1993 Audi 90q - 12vt


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 Post subject: Re: Anatomy of an over the top headlight setup.
PostPosted: Thu Mar 31, 2011 8:52 pm 
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mach 2 with my hair on fire

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I ran a similar setup in my 84' 4kq. Onlyt difference was that I used 8Lead to Relay block (Still plenty by my calculation) and 10 or 12ga to each light. Worked great but I still feel the 5ktq H4/H1 Aero Euro's I ran were better. As are the CQ H4/H1 Euro's. Highs on all are about the same. But on the 5ktq/CQ Euro/Aero setups the lows are better definded and seem to put out more light. I think its simply due to reflector size. 5x7 Rectangulars (Sport Quattro Style) also seem brighter on low, again I think because of the greater collector size.

Have fun, and make sure they are aimed correctly please.

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91' CQ Daily Driver (FOR SALE)
2000' A4 Avant ATQ
83' ur-quattro. "Jadis" Cage, Coilovers, No Engine Yet.
"Coupes are better than Sedans. Less Door Handles to replace!!!"

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 Post subject: Re: Anatomy of an over the top headlight setup.
PostPosted: Sun Apr 03, 2011 5:18 pm 
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and more pics please


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 Post subject: Re: Anatomy of an over the top headlight setup.
PostPosted: Thu Apr 07, 2011 4:09 pm 
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the_natrix wrote:
you can then make a mold of said glass in any cheap molding compound you can think of, make a replacement lens, hollow out the reflectors and mount elipsoid HID lamps inside?

yes it is alot more work, but the end result is a FAR superior setup in terms of looks, functionality, lumen output, ect.


kind of like this?

(We put GT3 RSR lenses over the lights when the car did sebring 12hr)

Image

996 GT3 RSR lights for reference:

(note removable lenses)

Image

I thought about it for a while, then the parts arrived, and I saw how much a set of Hella HID's in 55w trim cost.

That being said, the green 997 GT3 was THE brightest car at sebring at night, even brighter than the lighting on the front of WRC cars in night stages. (440w worth of HID will do that)

_________________
1989 200tq 192whp/247tq @14psi on CIS w/stock 10vt IC, stock turbo---*sold*
1989 200tq Avant K26/T04E 50 trim/AWIC/034 SIC...still CIS
1990 Audi 90 FWD ABZ tire melter.....in progress


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