<div dir="ltr"><div>Wonder why you want to replace the original relay ? - they are robust and although I have not opened one, the distinctive "click" that the contacts make indicates a decent set of contacts.</div><div>What is a modern relay ? A typical automotive 30A one with the plug in base and connection tails - not much smaller than the original ?</div><div>This relay is coil operated so minimal current is required at W2 and W1 (WP colour) terminals. <br></div><div>Now regarding the wire what do you mean by thinner wire ? is this perhaps 22 ga or ?</div><div>The issue to be aware of is not so much the wire current rating but the short circuit time ability.</div><div>The OD relay is fed by an ignition switched white wire W that is unfused and sourced directly from A3 at the fuse block.This has the full battery fault current (oomph) behind it. So if you are determined to change the W wire X section you should install an inline fuse as close as possible to the fuse block terminal. A 15 or 20 A fuse would probably be OK.
You don't want your new thinner wire to become a fuse in the event of a fault. <br></div><div>rg</div><div>BTW have made a simplified OD wiring diagram that might make things easier ....</div><div>LMK if you want a copy.<br></div></div><br><div class="gmail_quote"><div dir="ltr" class="gmail_attr">On Mon, Sep 18, 2023 at 2:11 AM john harper <<a href="mailto:ah100tech@gmail.com" target="_blank">ah100tech@gmail.com</a>> wrote:<br></div><blockquote class="gmail_quote" style="margin:0px 0px 0px 0.8ex;border-left:1px solid rgb(204,204,204);padding-left:1ex"><div dir="ltr">Simon<div><br></div><div>If you use thinner wire to the overdrive relay it will add resistance to the heavy coil and reduce its 'pull' and this might cause a slow overdrive engagement. In the limit, it might not even pull the armature high enough to disconnect the heavy coil which might then overheat including the thinner wire you are suggesting. This might then be a fire hazard.</div><div><br></div><div>All of this might be the worst case and perhaps I am being alarmist but why modify something that worked? They knew what they were doing when they originally designed the car electrics.</div></div><br><div class="gmail_quote"><div dir="ltr" class="gmail_attr">On Sun, 17 Sept 2023 at 22:03, Simon Lachlan via Healeys <<a href="mailto:healeys@autox.team.net" target="_blank">healeys@autox.team.net</a>> wrote:<br></div><blockquote class="gmail_quote" style="margin:0px 0px 0px 0.8ex;border-left:1px solid rgb(204,204,204);padding-left:1ex"><div><div lang="EN-GB"><div><p class="MsoNormal">I am putting a modern relay into my OD relay. Done it before with both the 8-way flasher box and the OD relay. Works well, though this one only managed +/-10 years. 10 years, but not so very many miles…<u></u><u></u></p><p class="MsoNormal">Anyhow……it’s a really tight fit in there and I thought I might save some space with thinner wires this time. What does the team think about the ampage flowing around in there? Is there much and is it constant when the car’s in OD or is it just a short burst to activate the coil and energize the solenoid? I’m thinking that bigger wires means less space (Harder to bend into little spaces) and thinner wires means overheating and consequent problems…..<u></u><u></u></p><p class="MsoNormal">Simon<u></u><u></u></p></div></div>_______________________________________________<br>
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