Hot wires

[FranklinLeicester]

I fitted new (Indian) headlights to my Marlin 3 years ago but the only time I use them is for the MOT test. However the other day I was out at dusk and the headlights went out for a few seconds then came on again after a bit of footling around with the Marina control stick. Checked next day under the bonnet and other places and noticed 2 wires on the back of the solenoid were hot to the touch when the headlights were switched on but not when the sidelights only were on. No other electrical circuits such as the ignition heat the wires up, just the headlights. See photos - the 2 wires are the white ones in the centre of the bunch of 4.
I wonder if the 3 things are connected - 1. New headlights and bulbs; 2. The temporary failure; 3. The hot wires. Any ideas?

[martinclan56]

That's a strange place to have a lot of wires connected. Doesn't seem right to me. If you don't already know, I suggest you trace them and see where they go. It doesn't take much to go from hot wires to electrical fire.
Ideally headlights should be individually fused and operated by relays. Particularly if they are higher power halogens.

[928cdu]

It looks like you’ve got stuff wired to the permanent live side of the solenoid .. not good practice .. it’s been done either because of no space on the fuse box (get a bigger fuse box) or possibly because stuff was causing fuses to blow. As previously stated .. trace back what these wires are feeding and if necessary add another fuse box or a bigger one and divert thru that ..

[FranklinLeicester]

Yes, I agree about the fire danger. I’ll check the bulbs to see if they are anything other than old fashioned things I’m used to. Never had any trouble in the 23 years I’ve had the car so never had cause to ferret around the wiring loom as I did on this occasion.

[Ye Ol Ripper]

How many "ways" on your current fusebox? Are there any spare ways to add another fuse to it & connect your headlights to that fusebox?

Please can you explian what an Indian headlight is and is it sealed beam, standard halogens eg 55 watt bulbs or are they higher wattage bulbs?

[HairyDave]

If you are using the donor's switchgear it is probably 40+ years old, It would be a kindness to put relays in the high draw (headlights & spotlights) with nice heavy feed wires with fuses.

[FranklinLeicester]

OK, thanks for all the good advice and suggestions. Firstly, I’ll check the bulbs and if necessary replace them with some old ones I have in stock, probably lower wattage. I didn’t replace the lamps for better lighting as I rarely go out in the dark but for cosmetic reasons. They were made in India. Secondly, even if this cures the problem I’ll get my “very busy at the moment” auto electrician chum on the case and ask his opinion on your various comments.

[MOC Chair]

I don't think that the lights going out will have anything to do with the hot wires. It is likely to be a problem with the headlight dip switch.
l once had a problem on a landrover where going from full to dip the lights went out momentarily each time. A new control stalk solved the problem.
lt may be possible to service a Marina switch if it will come apart. Some year ago we had trouble with the indicators on a Roadster which proved to be caused by a bad connection in the hazard warning light switch. I was able to take this to pieces and clean the rollers which were inside and we had no more problems.

[FranklinLeicester]

Yes, I agree Doug. I’ll sort that one out when this problem is fixed.

[FranklinLeicester]

I tried some old bulbs but they were the same 60/55w as the new ones. I’m not qualified or confident enough to make alterations to the system so I’ll leave it to my sparky pal who is. Thanks for your interest and suggestions which I’ll pass on.