Headlight Conversion

As I'm still waiting on my CarDisc parts manual, excuse my ignorance but would it be feasible to, or better still, has anyone had experience with converting the original headlights on a '79 116 GTV coupe over to a modern halogen set up?

The parabolas in my headlights have lost all their silver and I thought if I'm going to replace them anyway, why not update for better night light?

If this has been done, can anyone provide info on the process and if possible, the brands and part numbers used. If not, maybe just a good general discussion on the pros and cons will do. Cheers, Chris

I have done this on my Spider and it was dead easy to swap the old 7" units with standard H4 ones. I just used cheapo ones from a company called Ring and it cost me less than 40 quid including bulbs. You could probably spend more money to get something similar from Hella or others.

One thing you really must do if you go to halogens, but it's a good idea even if you don't, is to rewire the headlamp circuit to use relays instead of pushing a whole load of amps through the fragile stalk switch.

Hey Cosmo,
Thanks for the tip. I'll see if they've got an online store!
Good point about the relays - taa for that.

Cheers,

Chris

Hi,

Sorry but can I ask why it would be a good idea to add a relay? I am new to car electrics and am keen to understand why this is a good idea.

Thanks

The wiring on early Alfas is "basic" to say the least. The headlight circuit draws many amps and is run directly through the stalk switch. When you switch a lot of amps you need a good quality switch or a cheap one that can be replaced when the contacts burn out. The Alfa stalk switch is neither good quality nor cheap To fix the problem it is pretty easy to add a couple of relays to the circuit so the stalk switch only has to switch the small amount of power needed to actuate the relay. That saves the switch and puts the load onto the relay which is generally less compromised than a switch and a lot cheaper anyway.

Here's one I made earlier.

That's the best explaination I have seen.
Thank you.
Would adding a relay stop my volt meter dipping so much when I switch on my headlamps, or use the windscreen wipers?

It wouldn't stop the voltage drop, unless part of the original wiring had a resistance short somewhere and was using up power - but you'd probably notice that already from the burning smell

That kind of voltage drop normally indicates you don't have enough alternator output. Check the belt tension and check the connections to the alternator. If you have a voltmeter check the real voltage drop with and without the engine running. You may find the dash volt meter is only "Alfa accurate".

Thanks for your help. I must admit I was not aware of the Alfa Accurate thingy. I guess I have a lot to learn.

A fuse in the main 12volt feed would be a good idear if you are feeding the cable around the engine area.

Yeah, thanks Cosmo,

That is a really good idea and a really good explaination and post. A picture paints a thousand words as they say. You could never have got me to understand that as well without the photo.

Idea: perhaps you could publish the wiring diagram and cutting list (lengths of cable and required parts) for those of us not as electronically gifted as yourself. Thanks in advance.

Cheers mate,

Chris (....presently scounging around for terminals and cable snips)

I could give a list of parts and a wiring diagram for what I did with my Spider but I'm not sure how applicable it would be to other Alfa's. The wire lengths will depend on where you want to position the relays/fuses and where your battery is.

But I'll see what I can do if I get a spare hour or so in the next couple of days.

Originally Posted by Cosmo

I could give a list of parts and a wiring diagram for what I did with my Spider but I'm not sure how applicable it would be to other Alfa's. The wire lengths will depend on where you want to position the relays/fuses and where your battery is.

But I'll see what I can do if I get a spare hour or so in the next couple of days.

Without wanting to put you out too much, maybe just the correct specifications for the various components would do with a basic diagram show us how to fit it together. Is that a lot of work? If so, don't worry about it. It was just such a good idea that it seems worthwhile documenting it properly.

You probably hate me now!

Many thanks,

Chris (....ducking for cover from flying 'relay' projectile thingies)

Cibié did a very good halogen conversion kit for this car and the units are still not too difficult to come by.

Could you tell us what the relays are ? ie what we are looking to buy . Are they job specific or are they multi purpose ?

I have h4 's and no relays so will be adding relays to mine !! but have the added fun of finding what I need in German !

Thanks for the picture .!

Chris,
Converting headlamps on a 116 is not that easy as, unlike a Spider which has a pretty standard 7" unit, the Alfetta lamps are a bit more special. I've heard that some people have managed to fit BMW round units which are about the right size, but you need to butcher the fittings. If the Aus cars are the same as UK, there is talk of a batch of new RHD headlamps being made - speak to Chris at Highwood motors here in the UK.