3D Print File for high beam latching relay

[dandeluca]

For the good of the cause I have creating a 3D printable housing that makes it easy to implement Dave Barton's alternative to the original high beam latching relay. It plugs into the stock harness, you don't have to make any changes to the car's wiring and it should be easy to swap out the new relays if the need arises.



You can download the files here.

Volvo 240 High Beam Latching Relay Housing by dandeluca

The original high beam latching relay for the Volvo 240 is no longer available from Volvo and becoming increasingly expensive to procure. This housing allows you to easily hook up two common relays to replace the original volvo relay. You will have to make no modifications to the car's wiring...

www.thingiverse.com

The relays used are:
Porsche BMW Multi Purpose Relay
BOS-0332019109

Porsche Headlight Relay
DAN-989437B

After you print the two files you have to make up some pigtail wires and label them to match the pin numbers embossed on the print. (I did not use the actual pin numbers) Then epoxy the pins in. After that you simply have to match up the numbers to the ones printed on the lid. The lid snaps tightly closed.



Possible issues

• I used fairly stiff 16ga wire and the box is pretty tall. It's a tight fit in the original location.
• On my Volvo they only used the two outer pins of this wiring harness, yours may differ. Double check before you epoxy in the pigtails.
• 
• The standard relay I used is only 30A you may want to procure a 40A version.

Hope this helps someone, let me know if you have any questions.

 

[Radtap]

There is wire with a silicone coating you could use instead, extremely flexible and would bring the size down a little bit, silicone coating isn't the best for cars but since it's encased in epoxy it shouldn't be an issue.

 

[dandeluca]

I think that would work well for this application. The box could be made a little shorter and pretty much be a perfect fit. It does work as is, but if anyone would like a small modification I could always do that.

 

[1968 volvo]

Very cool. You should drop this into the 3d printed parts thread too so it doesn’t get buried.