Headlight Switches

[Dan D.]

I am currently doing an in-depth investigation into C1 headlight switches - both original and reproduction. One of the problems of the past has been the blinking headlight syndrome with reproduction switches. This is caused by the circuit breaker internal to the switch not being able to handle the headlight current.

If anyone has one of these blinking switches and is willing to loan it to me I would love to test it free of charge. I would like to measure the actual current trip point. I can turn it within one week.

If so, please e-mail me at dandill@aol.com

-Dan-

[Bob W.]

Re: Headlight Switches

Dan you may want to post this on a tri- five site also i think they use the same switch

[William F.]

Re: Headlight Switches

Dan,
In another post I told you I ordered a Lectric Limited switch from CC for my "62. It came with a chip out of one side of the plastic part of switch. Are these the switches the ones with bad circuit breakers? I need to ask for replacement or return for credit and buy a NOS . What would you and others with experiences with headlight switches do? My car does have halogen brights.
Guess I need to let CC know my decision today.
Thanks

[William F.]

Re: Headlight Switches

Dan,
I talked to Lectric Limited. They say they've upgraded the internal breaker on the headlight switches they sell. They say headlights shouldn't 'blink" UNLESS you've got high powered halogens, like Hella, etc. They said regular halogens shouldn't draw enough current to trip breaker either, but if they do, need to check for corrosion on connections and bad grounds. My old switch has no problems with headlights (just bad rheostat), so, IF new one has correct breaker capacity, I shouldn't have headlight problems with it , either. I'll still send you my new switch for you to check.

[Francis F.]

Re: Headlight Switches

yes I have one also,bought a few years ago from C C.when I told them of the problem the agent said I was the only one to ever have a problem,and would not offer to correct.
and that was my last dealing with them.
do you know of a supplier with a proper switch for my 1960 corvette ?
Francis,

[Dan D.]

Re: Headlight Switches

Yes Bob, these switches are used across the Chevrolet line-up for several years, and possibly all of GM. The 58-63 switch, which are all the same, are used on passenger cars, Corvairs, and even trucks. I want to complete what I am doing first to prevent any disinformation and panicking anyone.

-Dan-

[Dan D.]

Re: Headlight Switches

Okay, sounds good Bill. They did not tell me this yesterday, but most of what we talked about was 55-57 switches. The problem I have is I don't know how much current the 58-63 Corvettes draw. I have measured my 57 with regular repro T3s, but the 58 and up are 4 headlight cars. I will test your new switch when I get it and tell you what the breaker current interrupt is. We'll go from there.

-Dan-

[Dan D.]

Re: Headlight Switches

Francis, do you still have that bad switch? If so I would love to test it. It sounds like the new Lectric Limited switches may work okay.

-Dan-

[Al R.]

Re: Headlight Switches

Gentlemen, I'm curious if the headlights on the C-1s will blink if the relay system is used to by-pass the headlight wires from actually going through the switch? Anyone have any knowledge on this? I know some members have installed these relays to prevent heat build up in the switches. Just wondering if this is a viable option for those that drive their cars and do not get them judged. Al

[Roger W.]

Re: Headlight Switches

The average current drawn by the 4 headlights before these switches have a problem, would be good information to have. Having know values when troubleshooting problems is a big help.


Roger

[Dan D.]

Re: Headlight Switches

Al, the relay will take the load off of the switch circuit breaker so the lights will not blink.

Buuuuuut, if one does this, then the headlights and wiring have no current protection - the circuit breaker is bypassed. So one should add a fuse or circuit breaker to the circuit or one could lose the harness - or worse if a short was to occur.

The best way to fix this problem is to get a correctly functioning headlight switch. Based on what I am doing, I am convinced that GM designed this circuit and switch absolutely correct. They could not have done it better. We just need to get better product from our suppliers. I will publish a complete report in a few days.

-Dan-

[Dan D.]

Re: Headlight Switches

Yes, I would love to know how much current 4 headlight cars draw. I need to know this for the headlight switch evaluation I am doing.

But there should be enough head room in the headlight switch circuit breaker to handle this. These systems generally worked fine when new, and that was 1958 and up - it is the replacement switches that have the problem. However, the original design may not have the capability to handle Halogen lights, which were not invented when these cars were designed and built.

Also coming into play here, is that the power budget for the car was approaching the limit of the old DC generators which were flat out at 25 amps. Recognizing this problem, GM somehow managed to get a another 5 amps out of those poor old generators in 1962. This of course was fixed in 1963 with the advent of the alternator.

-Dan-

[Bob W.]

Re: Headlight Switches

Dan
Have you tested the switches made by Standerd (ds156) that can be used until someone makes a good quality switch.

[Dan D.]

Re: Headlight Switches

No I haven't Bob. That is the equivalent 072 switch, 56,57. Standard may not make it. If you have one I would love to test it.

-Dan-

[Bob W.]

Re: Headlight Switches

Dan
If you look at rock auto theDS156 is listed for 57-59-63

Bob