"39 & otheryears, dim lights

[Don Cape Cod]

Bud's '39 has had dim headlights and he has been badgering me to correct the problem. Finally got to it. Turns out, there was only a little over 4 volts delivered to the bulb socket when the lights were on, either hi or low. There was a major voltage drop in the harness. Turns out that under that tin shield on the firewall, where the dash & headlight harness connect, the connection was warm to the touch. That is where the voltage drop was occuring.
Instead of replacing the old style connector & sleeve, I replaced it with the yellow (10/12 guage) modern crimp connectors. I also made sure by soldering the wires, as well as crimping.

I can tell you that from now on, when installing a new harness, I will use a modern spade type terminal. Would hope that I could get Tyree to incorporate this change in the next harness I order.

Bud's still not excited over the improved lights.

 

[jimTN]

Another major problem with early lights is the ground because of all the fenders, braces and frame mounts that the ground has to go thru. I solder a connection directly to the headlight reflecter and sneak a ground wire from it thru the conduit to the frame and attach after cleaning a good bare spot on the frame. Makes a world of difference.

 

[PeteVS]

I also made sure by soldering the wires, as well as crimping.

Did you solder before or after crimping? If you soldered BEFORE, and there's a voltage drop through the joint, it's possible that the heat could soften the solder and create a whole new problem.