Well, I recently discovered that the wiring for my Hella's has been getting hot as hell. To be more specific the fuse gets hot as hell, when I installed them I was poppin fuses left and right and to test things I put a big honkin fuse in there to get it to work (dumb I know but o well hasn't burnt to the ground yet) Anywho, anyone have any ideas as to how I can fix this. It's annoyin the crap outta me, I've tried all kinds of different grounds and whatnot and still does the same crap.

 

You need bigger wires. Have you upped the the wattage on the bulbs or are they stock. If they are the OG hella bulbs then yeah my guess is you are not getting the best of grounds make sure the ground area/bolt is clear of paint and roughed up to bare metal. Use star washers then a dab of dielectric grease to prevent corrosion.

 

Their silverstar bulbs but their the same wattage as stock. All my grounds are grounded at factory ground points, the one on the relay at the body ground next to the battery and the switch is grounded to the factory placed ground below the cup holder.

 

My guess is you need to go to heavier gauge wire connected directly to the battery and a higher rated relay, 60A? Your switching wires should be good just upgrade the lights current load wire. Or split your lights it into two systems, duplicating the wiring you already have installed.

 

Well, I redid the grounds at the lights and went back to the correct size fuse. I'm not poppin fuses ne more but the power wire inline fuse still gets so hot you can't even touch it.

 

Is your wire at least a 16awg? those bulbs can draw upto 125w and you would need at least a 16awg to be able to carry that load.

 

also another possiblity for a fuse to get hot, is that it is not making good contact in its holder.

 

How can I make sure I'm getting good fuse contact?

 

i tried to tell you its all in grounds and wire...i goto school for this stuff...its a very simple diagram to follow and hard to mess up....dig out the multimeter and find out what you are pulling for voltage....

 

Heres my grounds, the two for each light and the ground for the relay itself.