there's a boot that serves the same purpose. Sorry to hear that. but... The fuses for the headlights should have blown. -----Original Message----- From: Denis Dodson <coocoo@xxxxxxx> Sent: Friday, February 15, 2008 3:42 PM To: tcb@xxxxxxxxxxxxx Subject: [tcb] Re: Murray GRRR! Well, that was the problem, the wire goming into the headlight bucket has no grommet, so the wire between the headlight switch and the bucket wore through. There may have been a grommet there. I don't see much life span in a grommet. Maybe 5 or 10 years? --- Original Message ----- From: Will Wood To: tcb@xxxxxxxxxxxxx Sent: Friday, February 15, 2008 3:38 PM Subject: [tcb] Re: Murray GRRR! The stock factory configuration didn't have it. That's why the headlight switch on early busses always comes into play since there's an unfused link directly to the battery. I have a 50A fuse on my primary to cover this kind of problem. There's also abrasion that can come into play, make sure you have grommets around the wires where it goes through sheetmetal. I had a VW bus where the Battery + Wire to the starter grommet had "worn" and when I checked, the cable was already chewed through just to the copper where it went through the bulkhead. A little further and I would have toasted that bus. You have to love VW wiriring in it's minimalistic simplicity that also promoted new car sales. ;-) -----Original Message----- From: Denis Dodson Sent: Feb 15, 2008 3:32 PM To: tcb@xxxxxxxxxxxxx Subject: [tcb] Re: Murray GRRR! Ha! Already done that. Chuck and I put in a new harness 5 years ago or so. We were both wondering why this wire had no fuse. ----- Original Message ----- From: Will Wood To: tcb@xxxxxxxxxxxxx Sent: Friday, February 15, 2008 3:24 PM Subject: [tcb] Re: Murray GRRR! You've been bit by the "minimalistic" VW approach to wiring. You evidently had a wire short that wasn't fused, hence the 8 AWG wire coming from the solenoid to your headlight switch was feeding power. If it were me, I'd buy a new harness and rewire the bus. A new Harness (full) is less than $300 and it's safe insurance on 45+ year old wiring. -----Original Message----- From: Denis Dodson Sent: Feb 15, [The entire original message is not included]