headlight switch options

dbower

dbower

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My headlight switch has taken up a smoking habit when the lights have been on for a few minutes. Entertaining but not a long-term asset. Apparently the rheostat is going bad (after barely working anyway for the last decade or so).

My 72 CSA is VIN 2760806 and has an 8-blade switch. I have in hand another switch from a dearly departed donor coupe with 9 blades.

Apparently new 8-blade switches are NLA, and used ones are being hoarded as gold substitutes ($100+). I don't see any listed on the usual suspect sites (Jaymic, Max, W&N, Carl, etc). What are my options? Rumor has it that 2002 and E3 switches from the era are interchangeable. Can anyone confirm? What about Mercedes switches from back in the day? (I am willing to accept the loss in horsepower resulting from a M-B headlight switch.)

I'm also considering trying to bypass the rheostat function (dash lights on full bright, such as that is) and using my current switch. Anyone tried that? Thanks.
 
I rebuilt my headlight switch - bend the corner tabs to separate the halves and clean the contacts, expand the springs, and re-pack with axle grease. Then you'll have to epoxy it back together along with a zip-tie to hold it all in place securely. Now is crisp and smooth and lots of life left in it. Maybe worth a try before replacement.
 
Are you confident that the smoke is coming from the gauge light rheostat portion of the switch? If so, I would jumper around that part of the switch in a heartbeat, unless dimming your gauges is an important feature for you.

Might the smoke be coming from the low beam contacts? Adding a relay to the low beam headlight circuit will reduce the current handled by the headlight switch. This will both extend the switch life and result in brighter low beams.
 
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