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What gauge wire would you recommend, or what wattage should we limit ourselves to if keeping the 16 gauge wire? Would keeping the 16 gauge wire defeat the purpose?
IMO, 12ga. minimum on the secondary side of the relays.
Defeat the purpose? Even if you stick with the 16ga wiring the relays are a must for this conversion.
From a previous thread on this subject,
"The sealed beam headlamps used on these cars originally were at best 15-20watts. On a four headlamp car, that is about 3amps for the low beams and roughly 8 amps on all four high beams. All this current passes through the headlight switch, dimmer switch, and the bulkhead connector using 16ga. wiring. Upgrading to a four lamp system with 55/60 watt low beam H4s and 55 watt H1 high beams will bring that current draw to about 8amps on low beam and upwards of 17amps with all four high beams burning. The original 40-yearold switches, wiring and connectors will not last long at that rate. Do yourself a favor and install the relays and run at least 12ga. wires on the secondary side."
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