When I installed relays and Cibie headlamps in my cars, I used 10 gauge wire. That’s probably larger than I need since I’m using only 60/55 watt H4 bulbs and 55 watt H1 bulbs, but it can’t hurt.
I couldn’t find any good sockets locally that use 10 gauge wire. Most of the connectors were phenolic resin that used 16 gauge wire. I’d read about ceramic sockets for headlamps on the Internets but never looked for them in earnest. When I broke a soldered wired off of one my headlamp sockets while troubleshooting a non-working turn signal, I thought I should find a socket compatible with the rest of the robust wiring.
I found these ceramic sockets on eBay and bought four of them.
They’re OK quality. The cover, which has a plastic hinge, snaps closed after inserting the contacts. I had to trim the tabs that hold the cover closed with an X-Acto knife before it would close completely. I soldered the wire to the connectors before inserting them in the sockets. At least they worked with the 10 gauge wire.
One night, while driving through the grove of Eucalyptus trees on US 101 near San Juan Bautista, California, I realized that the sealed beam headlamps on my Alfetta were inadequate. This is the same road that Scottie Ferguson and Madeleine Elster (Jimmy Stewart and Kim Novak) took to Mission San Juan Bautista in the film Vertigo.
A modern car had pulled up next to me in the other lane and I suddenly saw the road ahead. That’s when I realized that I had to improve the lighting on the Alfa Romeo.
Research turned up 5.75 inch (146 mm) Cibie H4 (low beam) and H1 (high beam) headlamps for the quad setup I needed. For the H1 headlamp, I used Osram Silverstar bulbs (NOT Sylvania Silverstar) and for the H4, I used Narva Rangepower High Output Plus 30 bulbs.
This setup is more economical than the Cibie Complex Surface Reflector (CSR) headlamps and I’m only replacing the right side headlamps in my crashed into Alfetta. Osram Sylvania produces a Xenarc HID conversion kit I’ve seen for US$ 588.
I’ve read that installing relays was a good idea for the Alfa, since the factory setup has all the headlight current going through the switch on the steering column. Daniel Stern has covered this and other lighting topics so thoroughly that I didn’t have to look anywhere else.
Comparing the Cibie headlamps to sealed beams is literally like day and night.