Subject: Re: [Healeys] Replacement Turn Signal Relay.

From: "simon.lachlan--- via Healeys" <[email-masked]> <[email-masked]>
Date: Sun, 22 Mar 2026 10:42:08 +0000

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Regarding these contraptions, there is a third way. I've mentioned it to M =
before....one can gut the old relay and rebuild its internals with new, mod=
ern, relays. I've done two or three. The first because my original had gone=
 into terminal decay and the others because I'd bought clapped out original=
s at a boot fair. Anyhow, the first one's been in the car for some years no=
w and works fine. The others are in one of the "boxes of useful things I ma=
y need one day". I've done the same to overdrive relays. By the way, I don'=
t claim to be the first person to have done this!!
Simon
________________________________
From: Healeys <[email-masked]> on behalf of Michael Salter =
<[email-masked]>
Sent: 20 March 2026 16:23
To: [email-masked] <[email-masked]>
Subject: [Healeys] Replacement Turn Signal Relay.

All Big Healeys prior to the later Phase 2 BJ8 use a Lusas 33117 relay for =
the turn signals. This relay connects the appropriate lamps to the turn sig=
nal flasher unit, overriding the brake light switch on turns.
These Lucas relays were a very primitive (by today's standards) but very ro=
bust unit and could withstand a short circuit as often happens with the gla=
ss lens type 594 turn/side/brake lamps used on these models at least until =
the fuse blew.
Within these lamps it is very easy to produce a short to ground.
Over the last few years replacements for these relays have been provided, u=
nder the Lucas name and the same 33117 part number, which have been complet=
ely redesigned and incorporate 2 modern G2R-1-E relays.
I have purchased 2 of these modern style relays and both have failed becaus=
e the  G2R-1-E relay relays don't seem to be anywhere near as robust as the=
 originals and fail before the 35 amp fuse can protect them..
So, a word of caution, if you are using one of these (improved) cheapo repo=
 turn signal relays, be very careful to avoid short circuits in the turn/br=
ake/side lamps.
The attached pics are of the original type and the circuit board from the "=
improved" replacement.

M

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<head>
<meta http-equiv=3D"Content-Type" content=3D"text/html; charset=3Dus-ascii"=
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</head>
<body dir=3D"ltr">
<div style=3D"font-family: Aptos, Aptos_EmbeddedFont, Aptos_MSFontService, =
Calibri, Helvetica, sans-serif; font-size: 12pt; color: rgb(0, 0, 0);" clas=
s=3D"elementToProof">
Regarding these contraptions, there is a third way. I've mentioned it to M =
before....one can gut the old relay and rebuild its internals with new, mod=
ern, relays. I've done two or three. The first because my original had gone=
 into terminal decay and the others
 because I'd bought clapped out originals at a boot fair. Anyhow, the first=
 one's been in the car for some years now and works fine. The others are in=
 one of the &quot;boxes of useful things I may need one day&quot;. I've don=
e the same to overdrive relays. By the way,
 I don't claim to be the first person to have done this!!</div>
<div style=3D"font-family: Aptos, Aptos_EmbeddedFont, Aptos_MSFontService, =
Calibri, Helvetica, sans-serif; font-size: 12pt; color: rgb(0, 0, 0);" clas=
s=3D"elementToProof">
Simon</div>
<div id=3D"appendonsend"></div>
<hr style=3D"display:inline-block;width:98%" tabindex=3D"-1">
<div id=3D"divRplyFwdMsg" dir=3D"ltr"><font face=3D"Calibri, sans-serif" st=
yle=3D"font-size:11pt" color=3D"#000000"><b>From:</b> Healeys &lt;healeys-b=
[email-masked]&gt; on behalf of Michael Salter &lt;michaelsalter@gma=
il.com&gt;<br>
<b>Sent:</b> 20 March 2026 16:23<br>
<b>To:</b> [email-masked] &lt;[email-masked]&gt;<br>
<b>Subject:</b> [Healeys] Replacement Turn Signal Relay.</font>
<div>&nbsp;</div>
</div>
<div>
<div dir=3D"ltr">
<div dir=3D"ltr">
<div class=3D"x_gmail_default" style=3D"font-family:arial,sans-serif; font-=
size:small">
All Big Healeys prior to the later Phase 2 BJ8 use a Lusas 33117 relay for =
the turn signals. This relay connects the appropriate&nbsp;lamps to the tur=
n signal flasher unit, overriding&nbsp;the brake light switch on turns.</di=
v>
<div class=3D"x_gmail_default" style=3D"font-family:arial,sans-serif; font-=
size:small">
These Lucas relays were a very primitive&nbsp;(by today's standards) but ve=
ry robust unit and could withstand a short circuit as often happens with th=
e glass lens&nbsp;type&nbsp;594&nbsp;turn/side/brake lamps used on these mo=
dels at least until the fuse blew.</div>
<div class=3D"x_gmail_default" style=3D"font-family:arial,sans-serif; font-=
size:small">
Within these lamps it is very easy to produce a short to ground.</div>
<div class=3D"x_gmail_default" style=3D"font-family:arial,sans-serif; font-=
size:small">
Over the last few years replacements for these relays have been provided,&n=
bsp;under the Lucas&nbsp;name and the same 33117 part number, which have be=
en completely redesigned and incorporate 2 modern G2R-1-E relays.&nbsp;</di=
v>
<div class=3D"x_gmail_default" style=3D"font-family:arial,sans-serif; font-=
size:small">
I have purchased&nbsp;2 of these modern style&nbsp;relays and both have fai=
led because the&nbsp; G2R-1-E relay relays don't seem to be anywhere near a=
s robust as the originals and fail before the 35 amp fuse can protect them.=
&nbsp; &nbsp;</div>
<div class=3D"x_gmail_default" style=3D"font-family:arial,sans-serif; font-=
size:small">
So, a word of caution, if you are using one of these (improved) cheapo repo=
 turn signal relays, be very careful to avoid short circuits in the turn/br=
ake/side lamps.</div>
<div class=3D"x_gmail_default" style=3D"font-family:arial,sans-serif; font-=
size:small">
The attached&nbsp;pics are of the original type and the circuit board from =
the &quot;improved&quot; replacement.</div>
<div class=3D"x_gmail_default" style=3D"font-family:arial,sans-serif; font-=
size:small">
<br>
</div>
<div class=3D"x_gmail_default" style=3D"font-family:arial,sans-serif; font-=
size:small">
M&nbsp;</div>
<div class=3D"x_gmail_default" style=3D"font-family:arial,sans-serif; font-=
size:small">
<img alt=3D"image.png" width=3D"499" height=3D"466" data-outlook-trace=3D"F=
:1|T:1" src=3D"cid:ii_mmz3yra50"><br>
<img alt=3D"image.png" width=3D"499" height=3D"402" data-outlook-trace=3D"F=
:1|T:1" src=3D"cid:ii_mmz3z4y91"><br>
<br>
</div>
<div class=3D"x_gmail_default" style=3D"font-family:arial,sans-serif; font-=
size:small">
<br>
</div>
<div class=3D"x_gmail_default" style=3D"font-family:arial,sans-serif; font-=
size:small">
<br>
</div>
</div>
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</div>
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_______________________________________________

Archive: http://www.team.net/pipermail/healeys http://autox.team.net/archive/healeys

[email-masked]
http://autox.team.net/mailman/listinfo/healeys

--===============0091397012112882356==--

---

From: "[email-masked]" <[email-masked]>
Date: Sun, 22 Mar 2026 12:48:35 +0100 (CET)

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=20
=20
=20
=20
Michael,
Since it's almost the same topic, but what bothers me much more is=20
replacing the relays on the 6-cylinder Austin-Healeys.
The top screw that holds the relay is inaccessible with a screwdriver when=
=20
the cold air duct is installed. The same goes for
the upper cable clamps. Is there a trick to removing the faulty turn signal=
=20
relay and installing a replacement without removing
the cold air duct and potentially damaging or crumpling it?
Thank you for any helpful suggestions.
=20
=20
Josef Eckert=20
K=C3=B6nigswinter/Germany

=20

=20

=20

=20

=20

-----Original-Nachricht-----

Betreff: Re: [Healeys] Replacement Turn Signal Relay.

Datum: 2026-03-22T12:33:37+0100

Von: "simon.lachlan--- via Healeys" <[email-masked]>

An: "Michael Salter" <[email-masked]>, "[email-masked]"=20
<[email-masked]>

=20

=20

=20

Regarding these contraptions, there is a third way. I've mentioned it to M=
=20
before....one can gut the old relay and rebuild its internals with new,=20
modern, relays. I've done two or three. The first because my original had=
=20
gone into terminal decay and the others because I'd bought clapped out=20
originals at a boot fair. Anyhow, the first one's been in the car for some=
=20
years now and works fine. The others are in one of the "boxes of useful=20
things I may need one day". I've done the same to overdrive relays. By the=
=20
way, I don't claim to be the first person to have done this!!
Simon
=20
------------------------------------------------------------------------
From: Healeys <[email-masked]> on behalf of Michael Salter=
=20
<[email-masked]>
Sent: 20 March 2026 16:23
To: [email-masked] <[email-masked]>
Subject: [Healeys] Replacement Turn Signal Relay.
=20
All Big Healeys prior to the later Phase 2 BJ8 use a Lusas 33117 relay for=
=20
the turn signals. This relay connects the appropriate lamps to the turn=20
signal flasher unit, overriding the brake light switch on turns.
These Lucas relays were a very primitive (by today's standards) but very=20
robust unit and could withstand a short circuit as often happens with the=
=20
glass lens type 594 turn/side/brake lamps used on these models at least=20
until the fuse blew.
Within these lamps it is very easy to produce a short to ground.
Over the last few years replacements for these relays have been provided,=
=20
under the Lucas name and the same 33117 part number, which have been=20
completely redesigned and incorporate 2 modern G2R-1-E relays.=20
I have purchased 2 of these modern style relays and both have failed=20
because the  G2R-1-E relay relays don't seem to be anywhere near as robust=
=20
as the originals and fail before the 35 amp fuse can protect them.  =20
So, a word of caution, if you are using one of these (improved) cheapo repo=
=20
turn signal relays, be very careful to avoid short circuits in the=20
turn/brake/side lamps.
The attached pics are of the original type and the circuit board from the=
=20
"improved" replacement.
=20
M=20

=20
=20

=20

=EF=BB=BF
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<html><head><meta http-equiv=3D"Content-Type" content=3D"text/html; charset=
=3DUTF-8"/><title></title></head><body><div class=3D"pGxpHc"><header id=3D"=
gb" class=3D"gb_Ha gb_yb gb_Bd gb_Pd gb_e gb_1a gb_Xd" role=3D"banner"></he=
ader></div>
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<div class=3D"hgbeOc EjH7wc"><nav class=3D"U0xwnf" aria-labelledby=3D"ucj-2=
">
<div class=3D"cWQYBc">&nbsp;</div>
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<div class=3D"lRu31" dir=3D"ltr"><span class=3D"HwtZe" lang=3D"en"><span cl=
ass=3D"ryNqvb">Michael, </span></span></div>
<div class=3D"lRu31" dir=3D"ltr"><span class=3D"HwtZe" lang=3D"en"><span cl=
ass=3D"ryNqvb">Since it's almost the same topic, but what bothers me much m=
ore is replacing the relays on the 6-cylinder Austin-Healeys</span></span><=
span class=3D"HwtZe" lang=3D"en"><span class=3D"ryNqvb">.</span> </span></d=
iv>
<div class=3D"lRu31" dir=3D"ltr"><span class=3D"HwtZe" lang=3D"en"><span cl=
ass=3D"ryNqvb">The top screw that holds the relay is inaccessible with a sc=
rewdriver when the cold air duct is installed.</span> <span class=3D"ryNqvb=
">The same goes for </span></span></div>
<div class=3D"lRu31" dir=3D"ltr"><span class=3D"HwtZe" lang=3D"en"><span cl=
ass=3D"ryNqvb">the upper cable clamps.</span> <span class=3D"ryNqvb">Is the=
re a trick to removing the faulty turn signal relay and installing a replac=
ement without removing </span></span></div>
<div class=3D"lRu31" dir=3D"ltr"><span class=3D"HwtZe" lang=3D"en"><span cl=
ass=3D"ryNqvb">the cold air duct and potentially damagi</span></span><span =
class=3D"HwtZe" lang=3D"en"><span class=3D"ryNqvb">ng or crumpling it?</spa=
n> </span></div>
<div class=3D"lRu31" dir=3D"ltr"><span class=3D"HwtZe" lang=3D"en"><span cl=
ass=3D"ryNqvb">Thank you for any helpful suggestions.</span> </span></div>
<div class=3D"lRu31" dir=3D"ltr">&nbsp;</div>
<div class=3D"lRu31" dir=3D"ltr">&nbsp;</div>
<div class=3D"lRu31" dir=3D"ltr"><span class=3D"HwtZe" lang=3D"en"><span cl=
ass=3D"ryNqvb">Josef Eckert&nbsp;</span></span></div>
<div class=3D"lRu31" dir=3D"ltr"><span class=3D"HwtZe" lang=3D"en"><span cl=
ass=3D"ryNqvb">K&ouml;nigswinter/Germany</span></span></div>
</div>
</div>
</div>
</div>
</div>
</div>
</div>
</div>
</div>
<p><span style=3D"font-family:arial,helvetica,sans-serif;font-size:10pt;col=
or:#000000;text-decoration:none">&nbsp;</span></p>
<p><span style=3D"font-family:arial,helvetica,sans-serif;font-size:10pt;col=
or:#000000;text-decoration:none">&nbsp;</span></p>
<p>&nbsp;</p>
<p>&nbsp;</p>
<p>&nbsp;</p>
<p>-----Original-Nachricht-----</p>
<p>Betreff: Re: [Healeys] Replacement Turn Signal Relay.</p>
<p>Datum: 2026-03-22T12:33:37+0100</p>
<p>Von: "simon.lachlan--- via Healeys" &lt;[email-masked]&gt;</p>
<p>An: "Michael Salter" &lt;[email-masked]&gt;, "[email-masked]=
m.net" &lt;[email-masked]&gt;</p>
<p>&nbsp;</p>
<p>&nbsp;</p>
<p>&nbsp;</p>
<div style=3D"position: relative; color: #000000; font: 12px Arial,Helvetic=
a,sans-serif;">
<div class=3D"elementToProof" style=3D"font-family: Aptos, Aptos_EmbeddedFo=
nt, Aptos_MSFontService, Calibri, Helvetica, sans-serif; font-size: 12pt; c=
olor: #000000;">Regarding these contraptions, there is a third way. I've me=
ntioned it to M before....one can gut the old relay and rebuild its interna=
ls with new, modern, relays. I've done two or three. The first because my o=
riginal had gone into terminal decay and the others because I'd bought clap=
ped out originals at a boot fair. Anyhow, the first one's been in the car f=
or some years now and works fine. The others are in one of the "boxes of us=
eful things I may need one day". I've done the same to overdrive relays. By=
 the way, I don't claim to be the first person to have done this!!</div>
<div class=3D"elementToProof" style=3D"font-family: Aptos, Aptos_EmbeddedFo=
nt, Aptos_MSFontService, Calibri, Helvetica, sans-serif; font-size: 12pt; c=
olor: #000000;">Simon</div>
<div>&nbsp;</div>
<hr style=3D"display: inline-block; width: 98%;" tabindex=3D"-1">
<div dir=3D"ltr"><span style=3D"font-size: 11pt; color: #000000; font-famil=
y: Calibri, sans-serif;"><strong>From:</strong> Healeys &lt;healeys-bounces=
@autox.team.net&gt; on behalf of Michael Salter &lt;[email-masked]=
&gt;<br><strong>Sent:</strong> 20 March 2026 16:23<br><strong>To:</strong> =
[email-masked] &lt;[email-masked]&gt;<br><strong>Subject:</=
strong> [Healeys] Replacement Turn Signal Relay.</span>
<div>&nbsp;</div>
</div>
<div>
<div dir=3D"ltr">
<div dir=3D"ltr">
<div class=3D"x_gmail_default" style=3D"font-family: arial,sans-serif; font=
-size: small;">All Big Healeys prior to the later Phase 2 BJ8 use a Lusas 3=
3117 relay for the turn signals. This relay connects the appropriate&nbsp;l=
amps to the turn signal flasher unit, overriding&nbsp;the brake light switc=
h on turns.</div>
<div class=3D"x_gmail_default" style=3D"font-family: arial,sans-serif; font=
-size: small;">These Lucas relays were a very primitive&nbsp;(by today's st=
andards) but very robust unit and could withstand a short circuit as often =
happens with the glass lens&nbsp;type&nbsp;594&nbsp;turn/side/brake lamps u=
sed on these models at least until the fuse blew.</div>
<div class=3D"x_gmail_default" style=3D"font-family: arial,sans-serif; font=
-size: small;">Within these lamps it is very easy to produce a short to gro=
und.</div>
<div class=3D"x_gmail_default" style=3D"font-family: arial,sans-serif; font=
-size: small;">Over the last few years replacements for these relays have b=
een provided,&nbsp;under the Lucas&nbsp;name and the same 33117 part number=
, which have been completely redesigned and incorporate 2 modern G2R-1-E re=
lays.&nbsp;</div>
<div class=3D"x_gmail_default" style=3D"font-family: arial,sans-serif; font=
-size: small;">I have purchased&nbsp;2 of these modern style&nbsp;relays an=
d both have failed because the&nbsp; G2R-1-E relay relays don't seem to be =
anywhere near as robust as the originals and fail before the 35 amp fuse ca=
n protect them.&nbsp; &nbsp;</div>
<div class=3D"x_gmail_default" style=3D"font-family: arial,sans-serif; font=
-size: small;">So, a word of caution, if you are using one of these (improv=
ed) cheapo repo turn signal relays, be very careful to avoid short circuits=
 in the turn/brake/side lamps.</div>
<div class=3D"x_gmail_default" style=3D"font-family: arial,sans-serif; font=
-size: small;">The attached&nbsp;pics are of the original type and the circ=
uit board from the "improved" replacement.</div>
<div class=3D"x_gmail_default" style=3D"font-family: arial,sans-serif; font=
-size: small;">&nbsp;</div>
<div class=3D"x_gmail_default" style=3D"font-family: arial,sans-serif; font=
-size: small;">M&nbsp;</div>
<div class=3D"x_gmail_default" style=3D"font-family: arial,sans-serif; font=
-size: small;"><img src=3D"cid:1774180115843.577574.337e4f58c2dc4170f656788=
[email-masked]" alt=3D"image.png" width=3D"499" height=
=3D"466" data-outlook-trace=3D"F:1|T:1" data-id=3D"2170910176"><br><img src=
=3D"cid:1774180115854.577575.fbc207e1f948ab314e3bb0c2e28bfbb0a2eb0b0e@spica=
.telekom.de" alt=3D"image.png" width=3D"499" height=3D"402" data-outlook-tr=
ace=3D"F:1|T:1" data-id=3D"2170910188"><br><br></div>
<div class=3D"x_gmail_default" style=3D"font-family: arial,sans-serif; font=
-size: small;">&nbsp;</div>
<div class=3D"x_gmail_default" style=3D"font-family: arial,sans-serif; font=
-size: small;">&nbsp;</div>
</div>
</div>
</div>
</div>
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[email-masked]

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---

From: Michael Salter <[email-masked]>
Date: Sun, 22 Mar 2026 12:28:26 -0400

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You are absolutely correct josef.
This is my trick. Remove the left front wheel and find the weld-nut for
that screw.
Carefully grind off the end of the screw to the level of the weld-nut then,
very carefully, starting with a 1/16" dbit, drill out the 10/32 screw
without damaging the weld-nut too much.
This will release the top of the relay. Run a 10/32 tap through the
weld-nut then take out the 2 lower screws and tackle the 8 terminal screws.
Back in the day the relays weren't that expensive and we used to just
replace them when they were thought to be faulty however, I gathered up the
removed ones in a bin.
Last week, after the problems that I had with my second cheapo repo, I
pulled 5 of them out of the bin and checked them.
The biggest problem was getting the slot cheese head terminal screws out
without breaking them but a little carefully applied heat solved that.
Once I removed the covers and cleaned up the 8 terminals I was amazed that
every one, after a couple of very minor adjustments, could be made to work
perfectly.
Not one of the coils, the component that I had always suspected was the
most likely point of failure, had any sort of problem.
I now have 5 fully functional turn signal relays that I'm in the process of
refinishing.
Getting that top screw in will still be difficult but it can be done before
refitting the cover.

M

On Sun, Mar 22, 2026 at 7:48=E2=80=AFAM [email-masked] <
[email-masked]> wrote:

>
>
>
>
> Michael,
> Since it's almost the same topic, but what bothers me much more is
> The top screw that holds the relay is inaccessible with a screwdriver whe=
n
> the upper cable clamps. Is there a trick to removing the faulty turn
> signal relay and installing a replacement without removing
> Josef Eckert
> An: "Michael Salter" <[email-masked]>, "[email-masked]" =
<
> [email-masked]>
>
>
>
>
>
>
> Regarding these contraptions, there is a third way. I've mentioned it to =
M
> before....one can gut the old relay and rebuild its internals with new,
> modern, relays. I've done two or three. The first because my original had
> gone into terminal decay and the others because I'd bought clapped out
> originals at a boot fair. Anyhow, the first one's been in the car for som=
e
> years now and works fine. The others are in one of the "boxes of useful
> things I may need one day". I've done the same to overdrive relays. By th=
e
> ------------------------------
> *From:* Healeys <[email-masked]> on behalf of Michael
> Salter <[email-masked]>
> *Sent:* 20 March 2026 16:23
> *To:* [email-masked] <[email-masked]>
> *Subject:* [Healeys] Replacement Turn Signal Relay.
>
> All Big Healeys prior to the later Phase 2 BJ8 use a Lusas 33117 relay fo=
r
> the turn signals. This relay connects the appropriate lamps to the turn
> These Lucas relays were a very primitive (by today's standards) but very
> robust unit and could withstand a short circuit as often happens with the
> glass lens type 594 turn/side/brake lamps used on these models at least
> until the fuse blew.
> Over the last few years replacements for these relays have been
> provided, under the Lucas name and the same 33117 part number, which have
> been completely redesigned and incorporate 2 modern G2R-1-E relays.
> I have purchased 2 of these modern style relays and both have failed
> because the  G2R-1-E relay relays don't seem to be anywhere near as robus=
t
> as the originals and fail before the 35 amp fuse can protect them.
> So, a word of caution, if you are using one of these (improved) cheapo
> repo turn signal relays, be very careful to avoid short circuits in the
> turn/brake/side lamps.
> The attached pics are of the original type and the circuit board from the
> "improved" replacement.
>
> M
>
>
>
>
>
> =EF=BB=BF
>

--00000000000031658d064d9f697a
Content-Transfer-Encoding: quoted-printable

<div dir=3D"ltr"><div class=3D"gmail_default" style=3D"font-family:arial,sa=
ns-serif;font-size:small">You are absolutely correct josef.=C2=A0</div><div=
 class=3D"gmail_default" style=3D"font-family:arial,sans-serif;font-size:sm=
all">This is my trick. Remove the left front wheel and find the weld-nut=C2=
=A0for that screw.</div><div class=3D"gmail_default" style=3D"font-family:a=
rial,sans-serif;font-size:small">Carefully grind off the end of=C2=A0the sc=
rew to the level of the weld-nut=C2=A0then, very carefully, starting with a=
 1/16&quot; dbit, drill out the 10/32 screw without damaging the weld-nut t=
oo much.</div><div class=3D"gmail_default" style=3D"font-family:arial,sans-=
serif;font-size:small">This will release the top of the relay. Run a 10/32 =
tap through the weld-nut then take out the 2 lower screws and tackle the 8 =
terminal screws.</div><div class=3D"gmail_default" style=3D"font-family:ari=
al,sans-serif;font-size:small">Back in the day the relays weren&#39;t that =
expensive and we used to just replace them when they were thought to be fau=
lty however, I gathered up the removed ones in a bin.</div><div class=3D"gm=
ail_default" style=3D"font-family:arial,sans-serif;font-size:small">Last we=
ek, after the problems that I had with my second cheapo repo, I pulled 5 of=
 them out of the bin and checked them.</div><div class=3D"gmail_default" st=
yle=3D"font-family:arial,sans-serif;font-size:small">The biggest problem wa=
s getting the slot cheese head terminal screws out without breaking them bu=
t a little carefully applied heat solved that.</div><div class=3D"gmail_def=
ault" style=3D"font-family:arial,sans-serif;font-size:small">Once I removed=
 the covers and cleaned up the 8 terminals I was amazed that every one, aft=
er a couple of very minor adjustments, could be made to work perfectly.</di=
v><div class=3D"gmail_default" style=3D"font-family:arial,sans-serif;font-s=
ize:small">Not one of the coils, the component that I had always suspected =
was the most likely point of failure, had any sort of problem.</div><div cl=
ass=3D"gmail_default" style=3D"font-family:arial,sans-serif;font-size:small=
">I now have 5 fully functional turn signal relays that I&#39;m in the proc=
ess of refinishing.</div><div class=3D"gmail_default" style=3D"font-family:=
arial,sans-serif;font-size:small">Getting that top screw in will still be d=
ifficult but it can be done before refitting the cover.</div><div class=3D"=
gmail_default" style=3D"font-family:arial,sans-serif;font-size:small"><br><=
/div><div class=3D"gmail_default" style=3D"font-family:arial,sans-serif;fon=
t-size:small">M</div><div class=3D"gmail_default" style=3D"font-family:aria=
l,sans-serif;font-size:small"><br></div><div class=3D"gmail_default" style=
=3D"font-family:arial,sans-serif;font-size:small"><br></div></div><br><div =
class=3D"gmail_quote"><div dir=3D"ltr" class=3D"gmail_attr">On Sun, Mar 22,=
 2026 at 7:48=E2=80=AFAM <a href=3D"mailto:[email-masked]" target=
=3D"_blank">[email-masked]</a> &lt;<a href=3D"mailto:josef-eckert=
@t-online.de" target=3D"_blank">[email-masked]</a>&gt; wrote:<br>=
</div><blockquote class=3D"gmail_quote" style=3D"margin:0px 0px 0px 0.8ex;b=
order-left:1px solid rgb(204,204,204);padding-left:1ex"><div><div></div>
<div>
<div>
<div><u></u>
<div>=C2=A0</div>
<div>=C2=A0</div>
<div>=C2=A0</div>
<div>=C2=A0</div>
<u></u></div>
<div>
<div>
<div>
<div>
<div>
<div>
<div>
<div dir=3D"ltr"><span lang=3D"en"><span>Michael, </span></span></div>
<div dir=3D"ltr"><span lang=3D"en"><span>Since it&#39;s almost the same top=
ic, but what bothers me much more is replacing the relays on the 6-cylinder=
 Austin-Healeys</span></span><span lang=3D"en"><span>.</span> </span></div>
<div dir=3D"ltr"><span lang=3D"en"><span>The top screw that holds the relay=
 is inaccessible with a screwdriver when the cold air duct is installed.</s=
pan> <span>The same goes for </span></span></div>
<div dir=3D"ltr"><span lang=3D"en"><span>the upper cable clamps.</span> <sp=
an>Is there a trick to removing the faulty turn signal relay and installing=
 a replacement without removing </span></span></div>
<div dir=3D"ltr"><span lang=3D"en"><span>the cold air duct and potentially =
damagi</span></span><span lang=3D"en"><span>ng or crumpling it?</span> </sp=
an></div>
<div dir=3D"ltr"><span lang=3D"en"><span>Thank you for any helpful suggesti=
ons.</span> </span></div>
<div dir=3D"ltr">=C2=A0</div>
<div dir=3D"ltr">=C2=A0</div>
<div dir=3D"ltr"><span lang=3D"en"><span>Josef Eckert=C2=A0</span></span></=
div>
<div dir=3D"ltr"><span lang=3D"en"><span>K=C3=B6nigswinter/Germany</span></=
span></div>
</div>
</div>
</div>
</div>
</div>
</div>
</div>
</div>
</div>
<p><span style=3D"font-family:arial,helvetica,sans-serif;font-size:10pt;col=
or:rgb(0,0,0);text-decoration:none">=C2=A0</span></p>
<p><span style=3D"font-family:arial,helvetica,sans-serif;font-size:10pt;col=
or:rgb(0,0,0);text-decoration:none">=C2=A0</span></p>
<p>=C2=A0</p>
<p>=C2=A0</p>
<p>=C2=A0</p>
<p>-----Original-Nachricht-----</p>
<p>Betreff: Re: [Healeys] Replacement Turn Signal Relay.</p>
<p>Datum: 2026-03-22T12:33:37+0100</p>
<p>Von: &quot;simon.lachlan--- via Healeys&quot; &lt;<a href=3D"mailto:heal=
[email-masked]" target=3D"_blank">[email-masked]</a>&gt;</p>
<p>An: &quot;Michael Salter&quot; &lt;<a href=3D"mailto:michaelsalter@gmail=
.com" target=3D"_blank">[email-masked]</a>&gt;, &quot;<a href=3D"m=
ailto:[email-masked]" target=3D"_blank">[email-masked]</a>&=
quot; &lt;<a href=3D"mailto:[email-masked]" target=3D"_blank">heale=
[email-masked]</a>&gt;</p>
<p>=C2=A0</p>
<p>=C2=A0</p>
<p>=C2=A0</p>
<div style=3D"color:rgb(0,0,0);font:12px Arial,Helvetica,sans-serif">
<div style=3D"font-family:Aptos,Aptos_EmbeddedFont,Aptos_MSFontService,Cali=
bri,Helvetica,sans-serif;font-size:12pt;color:rgb(0,0,0)">Regarding these c=
ontraptions, there is a third way. I&#39;ve mentioned it to M before....one=
 can gut the old relay and rebuild its internals with new, modern, relays. =
I&#39;ve done two or three. The first because my original had gone into ter=
minal decay and the others because I&#39;d bought clapped out originals at =
a boot fair. Anyhow, the first one&#39;s been in the car for some years now=
 and works fine. The others are in one of the &quot;boxes of useful things =
I may need one day&quot;. I&#39;ve done the same to overdrive relays. By th=
e way, I don&#39;t claim to be the first person to have done this!!</div>
<div style=3D"font-family:Aptos,Aptos_EmbeddedFont,Aptos_MSFontService,Cali=
bri,Helvetica,sans-serif;font-size:12pt;color:rgb(0,0,0)">Simon</div>
<div>=C2=A0</div>
<hr style=3D"display:inline-block;width:98%">
<div dir=3D"ltr"><span style=3D"font-size:11pt;color:rgb(0,0,0);font-family=
:Calibri,sans-serif"><strong>From:</strong> Healeys &lt;<a href=3D"mailto:h=
[email-masked]" target=3D"_blank">[email-masked]=
.net</a>&gt; on behalf of Michael Salter &lt;<a href=3D"mailto:michaelsalte=
[email-masked]" target=3D"_blank">[email-masked]</a>&gt;<br><strong>S=
ent:</strong> 20 March 2026 16:23<br><strong>To:</strong> <a href=3D"mailto=
:[email-masked]" target=3D"_blank">[email-masked]</a> &lt;<=
a href=3D"mailto:[email-masked]" target=3D"_blank">[email-masked]=
am.net</a>&gt;<br><strong>Subject:</strong> [Healeys] Replacement Turn Sign=
al Relay.</span>
<div>=C2=A0</div>
</div>
<div>
<div dir=3D"ltr">
<div dir=3D"ltr">
<div style=3D"font-family:arial,sans-serif;font-size:small">All Big Healeys=
 prior to the later Phase 2 BJ8 use a Lusas 33117 relay for the turn signal=
s. This relay connects the appropriate=C2=A0lamps to the turn signal flashe=
r unit, overriding=C2=A0the brake light switch on turns.</div>
<div style=3D"font-family:arial,sans-serif;font-size:small">These Lucas rel=
ays were a very primitive=C2=A0(by today&#39;s standards) but very robust u=
nit and could withstand a short circuit as often happens with the glass len=
s=C2=A0type=C2=A0594=C2=A0turn/side/brake lamps used on these models at lea=
st until the fuse blew.</div>
<div style=3D"font-family:arial,sans-serif;font-size:small">Within these la=
mps it is very easy to produce a short to ground.</div>
<div style=3D"font-family:arial,sans-serif;font-size:small">Over the last f=
ew years replacements for these relays have been provided,=C2=A0under the L=
ucas=C2=A0name and the same 33117 part number, which have been completely r=
edesigned and incorporate 2 modern G2R-1-E relays.=C2=A0</div>
<div style=3D"font-family:arial,sans-serif;font-size:small">I have purchase=
d=C2=A02 of these modern style=C2=A0relays and both have failed because the=
=C2=A0 G2R-1-E relay relays don&#39;t seem to be anywhere near as robust as=
 the originals and fail before the 35 amp fuse can protect them.=C2=A0 =C2=
=A0</div>
<div style=3D"font-family:arial,sans-serif;font-size:small">So, a word of c=
aution, if you are using one of these (improved) cheapo repo turn signal re=
lays, be very careful to avoid short circuits in the turn/brake/side lamps.=
</div>
<div style=3D"font-family:arial,sans-serif;font-size:small">The attached=C2=
=A0pics are of the original type and the circuit board from the &quot;impro=
ved&quot; replacement.</div>
<div style=3D"font-family:arial,sans-serif;font-size:small">=C2=A0</div>
<div style=3D"font-family:arial,sans-serif;font-size:small">M=C2=A0</div>
<div style=3D"font-family:arial,sans-serif;font-size:small"><img src=3D"cid=
:ii_19d164fc60fcb971f161" alt=3D"image.png" width=3D"499" height=3D"466"><b=
r><img src=3D"cid:ii_19d164fc610cb971f162" alt=3D"image.png" width=3D"499" =
height=3D"402"><br><br></div>
<div style=3D"font-family:arial,sans-serif;font-size:small">=C2=A0</div>
<div style=3D"font-family:arial,sans-serif;font-size:small">=C2=A0</div>
</div>
</div>
</div>
</div>
<p>=C2=A0</p>=EF=BB=BF</div></blockquote></div>

--00000000000031658d064d9f697a--

--00000000000031658f064d9f697b
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--00000000000031658f064d9f697b--

--===============3840771255950720468==
Content-Transfer-Encoding: 7bit
Content-Disposition: inline

[email-masked]

--===============3840771255950720468==--

---

From: Harold Manifold <[email-masked]>
Date: Sun, 22 Mar 2026 09:43:47 -0700

--===============0368270122824788918==

--000000000000f292ad064d9f9f68

--000000000000f292ac064d9f9f67
Content-Transfer-Encoding: quoted-printable

Hi,

When I restored my car, I opted for wire-reinforced ducting for the cold
air and heater ducts. While it is not concours correct, it looks very
similar to the original unless you look closely.

The primary advantage is that the wire-reinforced ducting is crush-proof
and can be easily moved out of the way to access those hidden screws.

Best regards,

Harold

On Sun, Mar 22, 2026 at 9:23=E2=80=AFAM Ken via Healeys <[email-masked]=
.net>
wrote:

> A couple of months ago, I gave up and cut the duct then inserted a sleeve
> for this same reason.
> Ken Freese
> 65 BJ8
>
>
>
> Sent from my Galaxy
>
>
> -------- Original message --------
> From: [email-masked]
> Date: 3/22/26 4:56 AM (GMT-08:00)
> To: Michael Salter <[email-masked]>, [email-masked]
> Subject: [Healeys] Replacement of Turn Signal Relay.
>
>
>
>
>
> Michael,
n
<
M
e
e
r
t
> Support Team.Net http://www.team.net/donate.html
> Suggested annual donation  $12.75
>
> Unsubscribe/Manage:
> http://autox.team.net/mailman/options/healeys/[email-masked]
>
>

--000000000000f292ac064d9f9f67
Content-Transfer-Encoding: quoted-printable

<div dir=3D"ltr"><div>Hi,</div><div><br></div><div>When I restored my car, =
I opted for wire-reinforced ducting for the cold air and heater ducts. Whil=
e it is not concours correct, it looks very similar to the original unless =
you look closely.</div><div><br></div><div>The primary advantage is that th=
e wire-reinforced ducting is crush-proof and can be easily moved out of the=
 way to access those hidden screws.</div><div><br></div><div>Best regards,<=
/div><div><br></div><div>Harold</div></div><br><div class=3D"gmail_quote gm=
ail_quote_container"><div dir=3D"ltr" class=3D"gmail_attr">On Sun, Mar 22, =
2026 at 9:23=E2=80=AFAM Ken via Healeys &lt;<a href=3D"mailto:healeys@autox=
.team.net">[email-masked]</a>&gt; wrote:<br></div><blockquote class=
=3D"gmail_quote" style=3D"margin:0px 0px 0px 0.8ex;border-left:1px solid rg=
b(204,204,204);padding-left:1ex"><div dir=3D"auto"><div dir=3D"auto">A coup=
le of months ago, I gave up and cut the duct then inserted a sleeve for thi=
s same reason.=C2=A0</div><div dir=3D"auto">Ken Freese</div><div dir=3D"aut=
o">65 BJ8</div><div dir=3D"auto"><br></div><div dir=3D"auto"><br></div><div=
 dir=3D"auto"><br></div><div id=3D"m_-793482278311650790composer_signature"=
 dir=3D"auto"><div style=3D"font-size:14px;color:rgb(144,144,144)" dir=3D"a=
uto">Sent from my Galaxy</div></div><div dir=3D"auto"><br></div><div><br></=
div><div align=3D"left" dir=3D"auto" style=3D"font-size:100%;color:rgb(0,0,=
0)"><div>-------- Original message --------</div><div>From: <a href=3D"mail=
to:[email-masked]" target=3D"_blank">[email-masked]</a>=
 </div><div>Date: 3/22/26  4:56 AM  (GMT-08:00) </div><div>To: Michael Salt=
er &lt;<a href=3D"mailto:[email-masked]" target=3D"_blank">michael=
[email-masked]</a>&gt;, <a href=3D"mailto:[email-masked]" target=
=3D"_blank">[email-masked]</a> </div><div>Subject: [Healeys] Replac=
ement of Turn Signal Relay. </div><div><br></div></div><div></div>
<div>
<div>
<div><u></u>
<div>=C2=A0</div>
<div>=C2=A0</div>
<div>=C2=A0</div>
<div>=C2=A0</div>
<u></u></div>
<div>
<div>
<div>
<div>
<div>
<div>
<div>
<div dir=3D"ltr"><span lang=3D"en"><span>Michael, </span></span></div>
<div dir=3D"ltr"><span lang=3D"en"><span>Since it&#39;s almost the same top=
ic, but what bothers me much more is replacing the relays on the 6-cylinder=
 Austin-Healeys</span></span><span lang=3D"en"><span>.</span> </span></div>
<div dir=3D"ltr"><span lang=3D"en"><span>The top screw that holds the relay=
 is inaccessible with a screwdriver when the cold air duct is installed.</s=
pan> <span>The same goes for </span></span></div>
<div dir=3D"ltr"><span lang=3D"en"><span>the upper cable clamps.</span> <sp=
an>Is there a trick to removing the faulty turn signal relay and installing=
 a replacement without removing </span></span></div>
<div dir=3D"ltr"><span lang=3D"en"><span>the cold air duct and potentially =
damagi</span></span><span lang=3D"en"><span>ng or crumpling it?</span> </sp=
an></div>
<div dir=3D"ltr"><span lang=3D"en"><span>Thank you for any helpful suggesti=
ons.</span> </span></div>
<div dir=3D"ltr">=C2=A0</div>
<div dir=3D"ltr">=C2=A0</div>
<div dir=3D"ltr"><span lang=3D"en"><span>Josef Eckert=C2=A0</span></span></=
div>
<div dir=3D"ltr"><span lang=3D"en"><span>K=C3=B6nigswinter/Germany</span></=
span></div>
</div>
</div>
</div>
</div>
</div>
</div>
</div>
</div>
</div>
<p><span style=3D"font-family:arial,helvetica,sans-serif;font-size:10pt;col=
or:rgb(0,0,0);text-decoration:none">=C2=A0</span></p>
<p><span style=3D"font-family:arial,helvetica,sans-serif;font-size:10pt;col=
or:rgb(0,0,0);text-decoration:none">=C2=A0</span></p>
<p>=C2=A0</p>
<p>=C2=A0</p>
<p>=C2=A0</p>
<p>-----Original-Nachricht-----</p>
<p>Betreff: Re: [Healeys] Replacement Turn Signal Relay.</p>
<p>Datum: 2026-03-22T12:33:37+0100</p>
<p>Von: &quot;simon.lachlan--- via Healeys&quot; &lt;<a href=3D"mailto:heal=
[email-masked]" target=3D"_blank">[email-masked]</a>&gt;</p>
<p>An: &quot;Michael Salter&quot; &lt;<a href=3D"mailto:michaelsalter@gmail=
.com" target=3D"_blank">[email-masked]</a>&gt;, &quot;<a href=3D"m=
ailto:[email-masked]" target=3D"_blank">[email-masked]</a>&=
quot; &lt;<a href=3D"mailto:[email-masked]" target=3D"_blank">heale=
[email-masked]</a>&gt;</p>
<p>=C2=A0</p>
<p>=C2=A0</p>
<p>=C2=A0</p>
<div style=3D"color:rgb(0,0,0);font:12px Arial,Helvetica,sans-serif">
<div style=3D"font-family:Aptos,Aptos_EmbeddedFont,Aptos_MSFontService,Cali=
bri,Helvetica,sans-serif;font-size:12pt;color:rgb(0,0,0)">Regarding these c=
ontraptions, there is a third way. I&#39;ve mentioned it to M before....one=
 can gut the old relay and rebuild its internals with new, modern, relays. =
I&#39;ve done two or three. The first because my original had gone into ter=
minal decay and the others because I&#39;d bought clapped out originals at =
a boot fair. Anyhow, the first one&#39;s been in the car for some years now=
 and works fine. The others are in one of the &quot;boxes of useful things =
I may need one day&quot;. I&#39;ve done the same to overdrive relays. By th=
e way, I don&#39;t claim to be the first person to have done this!!</div>
<div style=3D"font-family:Aptos,Aptos_EmbeddedFont,Aptos_MSFontService,Cali=
bri,Helvetica,sans-serif;font-size:12pt;color:rgb(0,0,0)">Simon</div>
<div>=C2=A0</div>
<hr style=3D"display:inline-block;width:98%">
<div dir=3D"ltr"><span style=3D"font-size:11pt;color:rgb(0,0,0);font-family=
:Calibri,sans-serif"><strong>From:</strong> Healeys &lt;<a href=3D"mailto:h=
[email-masked]" target=3D"_blank">[email-masked]=
.net</a>&gt; on behalf of Michael Salter &lt;<a href=3D"mailto:michaelsalte=
[email-masked]" target=3D"_blank">[email-masked]</a>&gt;<br><strong>S=
ent:</strong> 20 March 2026 16:23<br><strong>To:</strong> <a href=3D"mailto=
:[email-masked]" target=3D"_blank">[email-masked]</a> &lt;<=
a href=3D"mailto:[email-masked]" target=3D"_blank">[email-masked]=
am.net</a>&gt;<br><strong>Subject:</strong> [Healeys] Replacement Turn Sign=
al Relay.</span>
<div>=C2=A0</div>
</div>
<div>
<div dir=3D"ltr">
<div dir=3D"ltr">
<div style=3D"font-family:arial,sans-serif;font-size:small">All Big Healeys=
 prior to the later Phase 2 BJ8 use a Lusas 33117 relay for the turn signal=
s. This relay connects the appropriate=C2=A0lamps to the turn signal flashe=
r unit, overriding=C2=A0the brake light switch on turns.</div>
<div style=3D"font-family:arial,sans-serif;font-size:small">These Lucas rel=
ays were a very primitive=C2=A0(by today&#39;s standards) but very robust u=
nit and could withstand a short circuit as often happens with the glass len=
s=C2=A0type=C2=A0594=C2=A0turn/side/brake lamps used on these models at lea=
st until the fuse blew.</div>
<div style=3D"font-family:arial,sans-serif;font-size:small">Within these la=
mps it is very easy to produce a short to ground.</div>
<div style=3D"font-family:arial,sans-serif;font-size:small">Over the last f=
ew years replacements for these relays have been provided,=C2=A0under the L=
ucas=C2=A0name and the same 33117 part number, which have been completely r=
edesigned and incorporate 2 modern G2R-1-E relays.=C2=A0</div>
<div style=3D"font-family:arial,sans-serif;font-size:small">I have purchase=
d=C2=A02 of these modern style=C2=A0relays and both have failed because the=
=C2=A0 G2R-1-E relay relays don&#39;t seem to be anywhere near as robust as=
 the originals and fail before the 35 amp fuse can protect them.=C2=A0 =C2=
=A0</div>
<div style=3D"font-family:arial,sans-serif;font-size:small">So, a word of c=
aution, if you are using one of these (improved) cheapo repo turn signal re=
lays, be very careful to avoid short circuits in the turn/brake/side lamps.=
</div>
<div style=3D"font-family:arial,sans-serif;font-size:small">The attached=C2=
=A0pics are of the original type and the circuit board from the &quot;impro=
ved&quot; replacement.</div>
<div style=3D"font-family:arial,sans-serif;font-size:small">=C2=A0</div>
<div style=3D"font-family:arial,sans-serif;font-size:small">M=C2=A0</div>
<div style=3D"font-family:arial,sans-serif;font-size:small"><img height=3D"=
466" width=3D"499" alt=3D"image.png" src=3D"cid:ii_19d166ae7a1cb971f161" na=
me=3D"m_-793482278311650790_com_samsung_android_email_attachmentprovider_1_=
5203_RAW_1774196021846"><br><img height=3D"402" width=3D"499" alt=3D"image.=
png" src=3D"cid:ii_19d166ae7a2cb971f162" name=3D"m_-793482278311650790_com_=
samsung_android_email_attachmentprovider_1_5204_RAW_1774196021847"><br><br>=
</div>
<div style=3D"font-family:arial,sans-serif;font-size:small">=C2=A0</div>
<div style=3D"font-family:arial,sans-serif;font-size:small">=C2=A0</div>
</div>
</div>
</div>
</div>
<p>=C2=A0</p>=EF=BB=BF</div>_______________________________________________=
<br>
rer" target=3D"_blank">http://www.team.net/donate.html</a><br>
<br>
Archive: <a href=3D"http://www.team.net/pipermail/healeys" rel=3D"noreferre=
r" target=3D"_blank">http://www.team.net/pipermail/healeys</a> <a href=3D"h=
ttp://autox.team.net/archive/healeys" rel=3D"noreferrer" target=3D"_blank">=
http://autox.team.net/archive/healeys</a><br>
<br>
<a href=3D"mailto:[email-masked]" target=3D"_blank">[email-masked]=
eam.net</a><br>
<a href=3D"http://autox.team.net/mailman/listinfo/healeys" rel=3D"noreferre=
r" target=3D"_blank">http://autox.team.net/mailman/listinfo/healeys</a><br>
<br>
s/[email-masked]" rel=3D"noreferrer" target=3D"_blank">http://autox.tea=
m.net/mailman/options/healeys/[email-masked]</a><br>
<br>
</blockquote></div>

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[email-masked]

--===============0368270122824788918==--

---

From: "[email-masked]" <[email-masked]>
Date: Sun, 22 Mar 2026 19:06:36 +0100 (CET)

--===============3078927387356114677==
	boundary="----=_Part_1029931_1726966054.1774202796394"

------=_Part_1029931_1726966054.1774202796394
	boundary="----=_Part_1029932_1760799912.1774202796394"

------=_Part_1029932_1760799912.1774202796394
Content-Transfer-Encoding: quoted-printable

Hi Michael,

Thank you so much. Your method for removing and reinstalling the relay is=
=20
brilliant.

Unfortunately, I didn't come up with this promising solution. Simply so=20
easy, fantastic.

Thanks!=20

=20

Josef Eckert

K=C3=B6nigswinter / Germany

=20

=20

=20

=20

-----Original-Nachricht-----

Betreff: Re: Replacement of Turn Signal Relay.

Datum: 2026-03-22T17:28:44+0100

Von: "Michael Salter" <[email-masked]>

An: "[email-masked]" <[email-masked]>

=20

=20

=20

You are absolutely correct josef.=20
This is my trick. Remove the left front wheel and find the weld-nut for=20
that screw.
Carefully grind off the end of the screw to the level of the weld-nut then,=
=20
very carefully, starting with a 1/16" dbit, drill out the 10/32 screw=20
without damaging the weld-nut too much.
This will release the top of the relay. Run a 10/32 tap through the=20
weld-nut then take out the 2 lower screws and tackle the 8 terminal screws.
Back in the day the relays weren't that expensive and we used to just=20
replace them when they were thought to be faulty however, I gathered up the=
=20
removed ones in a bin.
Last week, after the problems that I had with my second cheapo repo, I=20
pulled 5 of them out of the bin and checked them.
The biggest problem was getting the slot cheese head terminal screws out=20
without breaking them but a little carefully applied heat solved that.
Once I removed the covers and cleaned up the 8 terminals I was amazed that=
=20
every one, after a couple of very minor adjustments, could be made to work=
=20
perfectly.
Not one of the coils, the component that I had always suspected was the=20
most likely point of failure, had any sort of problem.
I now have 5 fully functional turn signal relays that I'm in the process of=
=20
refinishing.
Getting that top screw in will still be difficult but it can be done before=
=20
refitting the cover.
=20
M
=20
=20

On Sun, Mar 22, 2026 at 7:48=E2=80=AFAM [email-masked]
  =20
  =20
  =20
  =20
  =20
  Michael,
  Since it's almost the same topic, but what bothers me much more is
  replacing the relays on the 6-cylinder Austin-Healeys.
  The top screw that holds the relay is inaccessible with a screwdriver
  when the cold air duct is installed. The same goes for
  the upper cable clamps. Is there a trick to removing the faulty turn
  signal relay and installing a replacement without removing
  the cold air duct and potentially damaging or crumpling it?
  Thank you for any helpful suggestions.
  =20
  =20
  Josef Eckert=20
  K=C3=B6nigswinter/Germany

  =20

  =20

  =20

  =20

  =20

  -----Original-Nachricht-----

  Von: "simon.lachlan--- via Healeys" <[email-masked]

  An: "Michael Salter" <[email-masked]

  =20

  =20

  =20

  Regarding these contraptions, there is a third way. I've mentioned it to
  M before....one can gut the old relay and rebuild its internals with new,
  modern, relays. I've done two or three. The first because my original had
  gone into terminal decay and the others because I'd bought clapped out
  originals at a boot fair. Anyhow, the first one's been in the car for
  some years now and works fine. The others are in one of the "boxes of
  useful things I may need one day". I've done the same to overdrive
  relays. By the way, I don't claim to be the first person to have done
  this!!
  Simon
  =20
  ----------------------------------------------------------------------
  From: Healeys <[email-masked]
  Sent: 20 March 2026 16:23
  Subject: [Healeys] Replacement Turn Signal Relay.
  =20
  All Big Healeys prior to the later Phase 2 BJ8 use a Lusas 33117 relay
  for the turn signals. This relay connects the appropriate lamps to the
  turn signal flasher unit, overriding the brake light switch on turns.
  These Lucas relays were a very primitive (by today's standards) but very
  robust unit and could withstand a short circuit as often happens with the
  glass lens type 594 turn/side/brake lamps used on these models at least
  until the fuse blew.
  Within these lamps it is very easy to produce a short to ground.
  Over the last few years replacements for these relays have been provided,
  under the Lucas name and the same 33117 part number, which have been
  completely redesigned and incorporate 2 modern G2R-1-E relays.=20
  I have purchased 2 of these modern style relays and both have failed
  because the  G2R-1-E relay relays don't seem to be anywhere near as
  robust as the originals and fail before the 35 amp fuse can protect them.
   =20
  So, a word of caution, if you are using one of these (improved) cheapo
  repo turn signal relays, be very careful to avoid short circuits in the
  turn/brake/side lamps.
  The attached pics are of the original type and the circuit board from the
  "improved" replacement.
  =20
  M=20

  =20
  =20

  =20

=20

=EF=BB=BF
------=_Part_1029932_1760799912.1774202796394
Content-Transfer-Encoding: quoted-printable

<html><head><meta http-equiv=3D"Content-Type" content=3D"text/html; charset=
=3DUTF-8"/><title></title></head><body><p><span style=3D"font-family: 'treb=
uchet ms', geneva, sans-serif; font-size: 12pt; color: #000000; text-decora=
tion: none;"><span class=3D"HwtZe" lang=3D"en"><span class=3D"ryNqvb">Hi Mi=
chael, </span></span></span></p>
<p><span style=3D"font-family: 'trebuchet ms', geneva, sans-serif; font-siz=
e: 12pt; color: #000000; text-decoration: none;"><span class=3D"HwtZe" lang=
=3D"en"><span class=3D"ryNqvb">Thank you so much.</span> <span class=3D"ryN=
qvb">Your method for removing and reinstalling the relay is brilliant.</spa=
n> </span></span></p>
<p><span style=3D"font-family: 'trebuchet ms', geneva, sans-serif; font-siz=
e: 12pt; color: #000000; text-decoration: none;"><span class=3D"HwtZe" lang=
=3D"en"><span class=3D"ryNqvb">Unfortunately, I didn't come up with this pr=
omising solution.</span><span class=3D"ryNqvb"> Simply so easy, fantastic.<=
/span> </span></span></p>
<p><span style=3D"font-family: 'trebuchet ms', geneva, sans-serif; font-siz=
e: 12pt; color: #000000; text-decoration: none;"><span class=3D"HwtZe" lang=
=3D"en"><span class=3D"ryNqvb">Thanks!&nbsp;</span></span></span></p>
<p>&nbsp;</p>
<p><span style=3D"font-family: 'trebuchet ms', geneva, sans-serif; font-siz=
e: 12pt; color: #000000; text-decoration: none;"><span class=3D"HwtZe" lang=
=3D"en"><span class=3D"ryNqvb">Josef Eckert </span></span></span></p>
<p><span style=3D"font-family: 'trebuchet ms', geneva, sans-serif; font-siz=
e: 12pt; color: #000000; text-decoration: none;"><span class=3D"HwtZe" lang=
=3D"en"><span class=3D"ryNqvb">K&ouml;nigswinter / Germany</span></span></s=
pan></p>
<p><span style=3D"font-family:arial,helvetica,sans-serif;font-size:10pt;col=
or:#000000;text-decoration:none">&nbsp;</span></p>
<p>&nbsp;</p>
<p>&nbsp;</p>
<p>&nbsp;</p>
<p>-----Original-Nachricht-----</p>
<p>Betreff: Re: Replacement of Turn Signal Relay.</p>
<p>Datum: 2026-03-22T17:28:44+0100</p>
<p>Von: "Michael Salter" &lt;[email-masked]&gt;</p>
<p>An: "[email-masked]" &lt;[email-masked]&gt;</p>
<p>&nbsp;</p>
<p>&nbsp;</p>
<p>&nbsp;</p>
<div style=3D"position: relative; color: #000000; font: 12px Arial,Helvetic=
a,sans-serif;">
<div dir=3D"ltr">
<div class=3D"gmail_default" style=3D"font-family: arial,sans-serif; font-s=
ize: small;">You are absolutely correct josef.&nbsp;</div>
<div class=3D"gmail_default" style=3D"font-family: arial,sans-serif; font-s=
ize: small;">This is my trick. Remove the left front wheel and find the wel=
d-nut&nbsp;for that screw.</div>
<div class=3D"gmail_default" style=3D"font-family: arial,sans-serif; font-s=
ize: small;">Carefully grind off the end of&nbsp;the screw to the level of =
the weld-nut&nbsp;then, very carefully, starting with a 1/16" dbit, drill o=
ut the 10/32 screw without damaging the weld-nut too much.</div>
<div class=3D"gmail_default" style=3D"font-family: arial,sans-serif; font-s=
ize: small;">This will release the top of the relay. Run a 10/32 tap throug=
h the weld-nut then take out the 2 lower screws and tackle the 8 terminal s=
crews.</div>
<div class=3D"gmail_default" style=3D"font-family: arial,sans-serif; font-s=
ize: small;">Back in the day the relays weren't that expensive and we used =
to just replace them when they were thought to be faulty however, I gathere=
d up the removed ones in a bin.</div>
<div class=3D"gmail_default" style=3D"font-family: arial,sans-serif; font-s=
ize: small;">Last week, after the problems that I had with my second cheapo=
 repo, I pulled 5 of them out of the bin and checked them.</div>
<div class=3D"gmail_default" style=3D"font-family: arial,sans-serif; font-s=
ize: small;">The biggest problem was getting the slot cheese head terminal =
screws out without breaking them but a little carefully applied heat solved=
 that.</div>
<div class=3D"gmail_default" style=3D"font-family: arial,sans-serif; font-s=
ize: small;">Once I removed the covers and cleaned up the 8 terminals I was=
 amazed that every one, after a couple of very minor adjustments, could be =
made to work perfectly.</div>
<div class=3D"gmail_default" style=3D"font-family: arial,sans-serif; font-s=
ize: small;">Not one of the coils, the component that I had always suspecte=
d was the most likely point of failure, had any sort of problem.</div>
<div class=3D"gmail_default" style=3D"font-family: arial,sans-serif; font-s=
ize: small;">I now have 5 fully functional turn signal relays that I'm in t=
he process of refinishing.</div>
<div class=3D"gmail_default" style=3D"font-family: arial,sans-serif; font-s=
ize: small;">Getting that top screw in will still be difficult but it can b=
e done before refitting the cover.</div>
<div class=3D"gmail_default" style=3D"font-family: arial,sans-serif; font-s=
ize: small;">&nbsp;</div>
<div class=3D"gmail_default" style=3D"font-family: arial,sans-serif; font-s=
ize: small;">M</div>
<div class=3D"gmail_default" style=3D"font-family: arial,sans-serif; font-s=
ize: small;">&nbsp;</div>
<div class=3D"gmail_default" style=3D"font-family: arial,sans-serif; font-s=
ize: small;">&nbsp;</div>
</div>
<br>
<div class=3D"gmail_quote">
<div class=3D"gmail_attr" dir=3D"ltr">On Sun, Mar 22, 2026 at 7:48=E2=80=AF=
AM <a href=3D"mailto:[email-masked]">[email-masked]</a>=
 &lt;<a href=3D"mailto:[email-masked]">[email-masked]</=
a>&gt; wrote:</div>
<blockquote class=3D"gmail_quote" style=3D"margin: 0px 0px 0px 0.8ex; borde=
r-left: 1px solid rgb(204,204,204); padding-left: 1ex;">
<div>
<div>&nbsp;</div>
<div>
<div>
<div>
<div>&nbsp;</div>
<div>&nbsp;</div>
<div>&nbsp;</div>
<div>&nbsp;</div>
</div>
<div>
<div>
<div>
<div>
<div>
<div>
<div>
<div dir=3D"ltr"><span lang=3D"en">Michael, </span></div>
<div dir=3D"ltr"><span lang=3D"en">Since it's almost the same topic, but wh=
at bothers me much more is replacing the relays on the 6-cylinder Austin-He=
aleys</span><span lang=3D"en">. </span></div>
<div dir=3D"ltr"><span lang=3D"en">The top screw that holds the relay is in=
accessible with a screwdriver when the cold air duct is installed. The same=
 goes for </span></div>
<div dir=3D"ltr"><span lang=3D"en">the upper cable clamps. Is there a trick=
 to removing the faulty turn signal relay and installing a replacement with=
out removing </span></div>
<div dir=3D"ltr"><span lang=3D"en">the cold air duct and potentially damagi=
</span><span lang=3D"en">ng or crumpling it? </span></div>
<div dir=3D"ltr"><span lang=3D"en">Thank you for any helpful suggestions. <=
/span></div>
<div dir=3D"ltr">&nbsp;</div>
<div dir=3D"ltr">&nbsp;</div>
<div dir=3D"ltr"><span lang=3D"en">Josef Eckert&nbsp;</span></div>
<div dir=3D"ltr"><span lang=3D"en">K&ouml;nigswinter/Germany</span></div>
</div>
</div>
</div>
</div>
</div>
</div>
</div>
</div>
</div>
<p><span style=3D"font-family: arial,helvetica,sans-serif; font-size: 10pt;=
 color: #000000; text-decoration: none;">&nbsp;</span></p>
<p><span style=3D"font-family: arial,helvetica,sans-serif; font-size: 10pt;=
 color: #000000; text-decoration: none;">&nbsp;</span></p>
<p>&nbsp;</p>
<p>&nbsp;</p>
<p>&nbsp;</p>
<p>-----Original-Nachricht-----</p>
<p>Betreff: Re: [Healeys] Replacement Turn Signal Relay.</p>
<p>Datum: 2026-03-22T12:33:37+0100</p>
<p>Von: "simon.lachlan--- via Healeys" &lt;<a href=3D"mailto:healeys@autox.=
team.net">[email-masked]</a>&gt;</p>
<p>An: "Michael Salter" &lt;<a href=3D"mailto:[email-masked]">mich=
[email-masked]</a>&gt;, "<a href=3D"mailto:[email-masked]">hea=
[email-masked]</a>" &lt;<a href=3D"mailto:[email-masked]">heal=
[email-masked]</a>&gt;</p>
<p>&nbsp;</p>
<p>&nbsp;</p>
<p>&nbsp;</p>
<div style=3D"color: #000000; font: 12px Arial,Helvetica,sans-serif;">
<div style=3D"font-family: Aptos,Aptos_EmbeddedFont,Aptos_MSFontService,Cal=
ibri,Helvetica,sans-serif; font-size: 12pt; color: #000000;">Regarding thes=
e contraptions, there is a third way. I've mentioned it to M before....one =
can gut the old relay and rebuild its internals with new, modern, relays. I=
've done two or three. The first because my original had gone into terminal=
 decay and the others because I'd bought clapped out originals at a boot fa=
ir. Anyhow, the first one's been in the car for some years now and works fi=
ne. The others are in one of the "boxes of useful things I may need one day=
". I've done the same to overdrive relays. By the way, I don't claim to be =
the first person to have done this!!</div>
<div style=3D"font-family: Aptos,Aptos_EmbeddedFont,Aptos_MSFontService,Cal=
ibri,Helvetica,sans-serif; font-size: 12pt; color: #000000;">Simon</div>
<div>&nbsp;</div>
<hr style=3D"display: inline-block; width: 98%;">
<div dir=3D"ltr"><span style=3D"font-size: 11pt; color: #000000; font-famil=
y: Calibri,sans-serif;"><strong>From:</strong> Healeys &lt;<a href=3D"mailt=
o:[email-masked]">[email-masked]</a>&gt; on=
 behalf of Michael Salter &lt;<a href=3D"mailto:[email-masked]">mi=
[email-masked]</a>&gt;<br><strong>Sent:</strong> 20 March 2026 16:23=
<br><strong>To:</strong> <a href=3D"mailto:[email-masked]">healeys@=
autox.team.net</a> &lt;<a href=3D"mailto:[email-masked]">healeys@au=
tox.team.net</a>&gt;<br><strong>Subject:</strong> [Healeys] Replacement Tur=
n Signal Relay.</span>
<div>&nbsp;</div>
</div>
<div>
<div dir=3D"ltr">
<div dir=3D"ltr">
<div style=3D"font-family: arial,sans-serif; font-size: small;">All Big Hea=
leys prior to the later Phase 2 BJ8 use a Lusas 33117 relay for the turn si=
gnals. This relay connects the appropriate&nbsp;lamps to the turn signal fl=
asher unit, overriding&nbsp;the brake light switch on turns.</div>
<div style=3D"font-family: arial,sans-serif; font-size: small;">These Lucas=
 relays were a very primitive&nbsp;(by today's standards) but very robust u=
nit and could withstand a short circuit as often happens with the glass len=
s&nbsp;type&nbsp;594&nbsp;turn/side/brake lamps used on these models at lea=
st until the fuse blew.</div>
<div style=3D"font-family: arial,sans-serif; font-size: small;">Within thes=
e lamps it is very easy to produce a short to ground.</div>
<div style=3D"font-family: arial,sans-serif; font-size: small;">Over the la=
st few years replacements for these relays have been provided,&nbsp;under t=
he Lucas&nbsp;name and the same 33117 part number, which have been complete=
ly redesigned and incorporate 2 modern G2R-1-E relays.&nbsp;</div>
<div style=3D"font-family: arial,sans-serif; font-size: small;">I have purc=
hased&nbsp;2 of these modern style&nbsp;relays and both have failed because=
 the&nbsp; G2R-1-E relay relays don't seem to be anywhere near as robust as=
 the originals and fail before the 35 amp fuse can protect them.&nbsp; &nbs=
p;</div>
<div style=3D"font-family: arial,sans-serif; font-size: small;">So, a word =
of caution, if you are using one of these (improved) cheapo repo turn signa=
l relays, be very careful to avoid short circuits in the turn/brake/side la=
mps.</div>
<div style=3D"font-family: arial,sans-serif; font-size: small;">The attache=
d&nbsp;pics are of the original type and the circuit board from the "improv=
ed" replacement.</div>
<div style=3D"font-family: arial,sans-serif; font-size: small;">&nbsp;</div=
<div style=3D"font-family: arial,sans-serif; font-size: small;">M&nbsp;</di=
v>
<div style=3D"font-family: arial,sans-serif; font-size: small;"><img src=3D=
"cid:[email-masked]=
lekom.de" alt=3D"image.png" width=3D"499" height=3D"466" data-id=3D"2171887=
768"><br><img src=3D"cid:1774202796093.617592.4c9a84c8d56d9b6af5164eb692026=
[email-masked]" alt=3D"image.png" width=3D"499" height=3D"402=
" data-id=3D"2171887774"><br><br></div>
<div style=3D"font-family: arial,sans-serif; font-size: small;">&nbsp;</div=
<div style=3D"font-family: arial,sans-serif; font-size: small;">&nbsp;</div=
</div>
</div>
</div>
</div>
<p>&nbsp;</p>
</div>
</blockquote>
</div>
</div>
<p>&nbsp;</p>=EF=BB=BF</body></html>
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[email-masked]

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---

From: "JSARCH" <[email-masked]>
Date: Sun, 22 Mar 2026 13:28:54 -0700

This is a multipart message in MIME format.

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I installed Poly-Butyl rubber air hose with a steel wire from =
Tom=E2=80=99s Import Toys. They can be moved around to access the turn =
signal indicator and they are much easier to work with if I need to =
remove the blower motor  I am very happy that I installed them.

=20

https://tomsimport.com/category/new-parts/air-hoses/

=20

Cheers,

John Spaur

=E2=80=9962 BT7

=20

From: Healeys <[email-masked]> On Behalf Of Harold =
Manifold
Sent: Sunday, March 22, 2026 9:44 AM
To: Ken <[email-masked]>
Cc: [email-masked]
Subject: Re: [Healeys] Replacement of Turn Signal Relay.

=20

Hi,

=20

When I restored my car, I opted for wire-reinforced ducting for the cold =
air and heater ducts. While it is not concours correct, it looks very =
similar to the original unless you look closely.

=20

The primary advantage is that the wire-reinforced ducting is crush-proof =
and can be easily moved out of the way to access those hidden screws.

=20

Best regards,

=20

Harold

=20

On Sun, Mar 22, 2026 at 9:23=E2=80=AFAM Ken via Healeys =

A couple of months ago, I gave up and cut the duct then inserted a =
sleeve for this same reason.=20

Ken Freese

65 BJ8

=20

=20

=20

Sent from my Galaxy

=20

=20

-------- Original message --------

Date: 3/22/26 4:56 AM (GMT-08:00)=20

To: Michael Salter <[email-masked] =

Subject: [Healeys] Replacement of Turn Signal Relay.=20

=20

=20

=20

=20

=20

Michael,=20

Since it's almost the same topic, but what bothers me much more is =
replacing the relays on the 6-cylinder Austin-Healeys.=20

The top screw that holds the relay is inaccessible with a screwdriver =
when the cold air duct is installed. The same goes for=20

the upper cable clamps. Is there a trick to removing the faulty turn =
signal relay and installing a replacement without removing=20

the cold air duct and potentially damaging or crumpling it?=20

Thank you for any helpful suggestions.=20

=20

=20

Josef Eckert=20

=20

=20

=20

=20

=20

-----Original-Nachricht-----

Von: "simon.lachlan--- via Healeys" <[email-masked] =

An: "Michael Salter" <[email-masked] =

=20

=20

=20

Regarding these contraptions, there is a third way. I've mentioned it to =
M before....one can gut the old relay and rebuild its internals with =
new, modern, relays. I've done two or three. The first because my =
original had gone into terminal decay and the others because I'd bought =
clapped out originals at a boot fair. Anyhow, the first one's been in =
the car for some years now and works fine. The others are in one of the =
"boxes of useful things I may need one day". I've done the same to =
overdrive relays. By the way, I don't claim to be the first person to =
have done this!!

Simon

=20

  _____ =20

From: Healeys <[email-masked] =
Sent: 20 March 2026 16:23
Subject: [Healeys] Replacement Turn Signal Relay.=20

=20

All Big Healeys prior to the later Phase 2 BJ8 use a Lusas 33117 relay =
for the turn signals. This relay connects the appropriate lamps to the =
turn signal flasher unit, overriding the brake light switch on turns.

These Lucas relays were a very primitive (by today's standards) but very =
robust unit and could withstand a short circuit as often happens with =
the glass lens type 594 turn/side/brake lamps used on these models at =
least until the fuse blew.

Over the last few years replacements for these relays have been =
provided, under the Lucas name and the same 33117 part number, which =
have been completely redesigned and incorporate 2 modern G2R-1-E relays. =

I have purchased 2 of these modern style relays and both have failed =
because the  G2R-1-E relay relays don't seem to be anywhere near as =
robust as the originals and fail before the 35 amp fuse can protect =
them.  =20

So, a word of caution, if you are using one of these (improved) cheapo =
repo turn signal relays, be very careful to avoid short circuits in the =
turn/brake/side lamps.

The attached pics are of the original type and the circuit board from =
the "improved" replacement.

=20

M=20

=20

=20

=20

=EF=BB=BF

Archive: http://www.team.net/pipermail/healeys =
http://autox.team.net/archive/healeys

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</o:shapelayout></xml><![endif]--></head><body lang=3DEN-US link=3Dblue =
vlink=3Dpurple style=3D'word-wrap:break-word'><div =
class=3DWordSection1><p class=3DMsoNormal><span =
style=3D'font-size:11.0pt;font-family:"Calibri",sans-serif'>I installed =
Poly-Butyl rubber air hose with a steel wire from Tom=E2=80=99s Import =
Toys. They can be moved around to access the turn signal indicator and =
they are much easier to work with if I need to remove the blower motor =
=C2=A0I am very happy that I installed them.<o:p></o:p></span></p><p =
class=3DMsoNormal><span =
style=3D'font-size:11.0pt;font-family:"Calibri",sans-serif'><o:p>&nbsp;</=
o:p></span></p><p class=3DMsoNormal><span =
style=3D'font-size:11.0pt;font-family:"Calibri",sans-serif'><a =
href=3D"https://tomsimport.com/category/new-parts/air-hoses/">https://tom=
simport.com/category/new-parts/air-hoses/</a><o:p></o:p></span></p><p =
class=3DMsoNormal><span =
style=3D'font-size:11.0pt;font-family:"Calibri",sans-serif'><o:p>&nbsp;</=
o:p></span></p><p class=3DMsoNormal><span =
style=3D'font-size:11.0pt;font-family:"Calibri",sans-serif'>Cheers,<o:p><=
/o:p></span></p><p class=3DMsoNormal><span =
style=3D'font-size:11.0pt;font-family:"Calibri",sans-serif'>John =
Spaur<o:p></o:p></span></p><p class=3DMsoNormal><span =
style=3D'font-size:11.0pt;font-family:"Calibri",sans-serif'>=E2=80=9962 =
BT7<o:p></o:p></span></p><p class=3DMsoNormal><span =
style=3D'font-size:11.0pt;font-family:"Calibri",sans-serif'><o:p>&nbsp;</=
o:p></span></p><div style=3D'border:none;border-top:solid #E1E1E1 =
1.0pt;padding:3.0pt 0in 0in 0in'><p class=3DMsoNormal><b><span =
style=3D'font-size:11.0pt;font-family:"Calibri",sans-serif'>From:</span><=
/b><span style=3D'font-size:11.0pt;font-family:"Calibri",sans-serif'> =
Healeys &lt;[email-masked]&gt; <b>On Behalf Of =
</b>Harold Manifold<br><b>Sent:</b> Sunday, March 22, 2026 9:44 =
AM<br><b>To:</b> Ken &lt;[email-masked]&gt;<br><b>Cc:</b> =
[email-masked]<br><b>Subject:</b> Re: [Healeys] Replacement of =
Turn Signal Relay.<o:p></o:p></span></p></div><p =
class=3DMsoNormal><o:p>&nbsp;</o:p></p><div><div><p =
class=3DMsoNormal>Hi,<o:p></o:p></p></div><div><p =
class=3DMsoNormal><o:p>&nbsp;</o:p></p></div><div><p =
class=3DMsoNormal>When I restored my car, I opted for wire-reinforced =
ducting for the cold air and heater ducts. While it is not concours =
correct, it looks very similar to the original unless you look =
closely.<o:p></o:p></p></div><div><p =
class=3DMsoNormal><o:p>&nbsp;</o:p></p></div><div><p =
class=3DMsoNormal>The primary advantage is that the wire-reinforced =
ducting is crush-proof and can be easily moved out of the way to access =
those hidden screws.<o:p></o:p></p></div><div><p =
class=3DMsoNormal><o:p>&nbsp;</o:p></p></div><div><p =
class=3DMsoNormal>Best regards,<o:p></o:p></p></div><div><p =
class=3DMsoNormal><o:p>&nbsp;</o:p></p></div><div><p =
class=3DMsoNormal>Harold<o:p></o:p></p></div></div><p =
class=3DMsoNormal><o:p>&nbsp;</o:p></p><div><div><p class=3DMsoNormal>On =
Sun, Mar 22, 2026 at 9:23<span =
style=3D'font-family:"Arial",sans-serif'>=E2=80=AF</span>AM Ken via =
Healeys &lt;<a =
href=3D"mailto:[email-masked]">[email-masked]</a>&gt; =
wrote:<o:p></o:p></p></div><blockquote =
style=3D'border:none;border-left:solid #CCCCCC 1.0pt;padding:0in 0in 0in =
6.0pt;margin-left:4.8pt;margin-right:0in'><div><div><p =
class=3DMsoNormal>A couple of months ago, I gave up and cut the duct =
then inserted a sleeve for this same =
reason.&nbsp;<o:p></o:p></p></div><div><p class=3DMsoNormal>Ken =
Freese<o:p></o:p></p></div><div><p class=3DMsoNormal>65 =
BJ8<o:p></o:p></p></div><div><p =
class=3DMsoNormal><o:p>&nbsp;</o:p></p></div><div><p =
class=3DMsoNormal><o:p>&nbsp;</o:p></p></div><div><p =
class=3DMsoNormal><o:p>&nbsp;</o:p></p></div><div =
id=3D"m_-793482278311650790composer_signature"><div><p =
class=3DMsoNormal><span style=3D'font-size:10.5pt;color:#909090'>Sent =
from my Galaxy<o:p></o:p></span></p></div></div><div><p =
class=3DMsoNormal><o:p>&nbsp;</o:p></p></div><div><p =
class=3DMsoNormal><o:p>&nbsp;</o:p></p></div><div><p =
class=3DMsoNormal><span style=3D'color:black'>-------- Original message =
--------<o:p></o:p></span></p></div><div><p class=3DMsoNormal><span =
style=3D'color:black'>From: <a href=3D"mailto:[email-masked]" =
target=3D"_blank">[email-masked]</a> =
<o:p></o:p></span></p></div><div><p class=3DMsoNormal><span =
style=3D'color:black'>Date: 3/22/26 4:56 AM (GMT-08:00) =
<o:p></o:p></span></p></div><div><p class=3DMsoNormal><span =
style=3D'color:black'>To: Michael Salter &lt;<a =
href=3D"mailto:[email-masked]" =
target=3D"_blank">[email-masked]</a>&gt;, <a =
href=3D"mailto:[email-masked]" =
target=3D"_blank">[email-masked]</a> =
<o:p></o:p></span></p></div><div><p class=3DMsoNormal><span =
style=3D'color:black'>Subject: [Healeys] Replacement of Turn Signal =
Relay. <o:p></o:p></span></p></div><div><p class=3DMsoNormal><span =
style=3D'color:black'><o:p>&nbsp;</o:p></span></p></div><div><div><div><d=
iv><p class=3DMsoNormal>&nbsp;<o:p></o:p></p></div><div><p =
class=3DMsoNormal>&nbsp;<o:p></o:p></p></div><div><p =
class=3DMsoNormal>&nbsp;<o:p></o:p></p></div><div><p =
class=3DMsoNormal>&nbsp;<o:p></o:p></p></div></div><div><div><div><div><d=
iv><div><div><div><p class=3DMsoNormal><span lang=3DEN>Michael, =
</span><o:p></o:p></p></div><div><p class=3DMsoNormal><span =
lang=3DEN>Since it's almost the same topic, but what bothers me much =
more is replacing the relays on the 6-cylinder Austin-Healeys. =
</span><o:p></o:p></p></div><div><p class=3DMsoNormal><span =
lang=3DEN>The top screw that holds the relay is inaccessible with a =
screwdriver when the cold air duct is installed. The same goes for =
</span><o:p></o:p></p></div><div><p class=3DMsoNormal><span =
lang=3DEN>the upper cable clamps. Is there a trick to removing the =
faulty turn signal relay and installing a replacement without removing =
</span><o:p></o:p></p></div><div><p class=3DMsoNormal><span =
lang=3DEN>the cold air duct and potentially damaging or crumpling it? =
</span><o:p></o:p></p></div><div><p class=3DMsoNormal><span =
lang=3DEN>Thank you for any helpful suggestions. =
</span><o:p></o:p></p></div><div><p =
class=3DMsoNormal>&nbsp;<o:p></o:p></p></div><div><p =
class=3DMsoNormal>&nbsp;<o:p></o:p></p></div><div><p =
class=3DMsoNormal><span lang=3DEN>Josef =
Eckert&nbsp;</span><o:p></o:p></p></div><div><p class=3DMsoNormal><span =
lang=3DEN>K=C3=B6nigswinter/Germany</span><o:p></o:p></p></div></div></di=
v></div></div></div></div></div></div></div><p><span =
style=3D'font-size:10.0pt;font-family:"Arial",sans-serif;color:black'>&nb=
sp;</span><o:p></o:p></p><p><span =
style=3D'font-size:10.0pt;font-family:"Arial",sans-serif;color:black'>&nb=
sp;</span><o:p></o:p></p><p>&nbsp;<o:p></o:p></p><p>&nbsp;<o:p></o:p></p>=
<p>&nbsp;<o:p></o:p></p><p>-----Original-Nachricht-----<o:p></o:p></p><p>=
Betreff: Re: [Healeys] Replacement Turn Signal =
Relay.<o:p></o:p></p><p>Datum: =
2026-03-22T12:33:37+0100<o:p></o:p></p><p>Von: &quot;simon.lachlan--- =
via Healeys&quot; &lt;<a href=3D"mailto:[email-masked]" =
target=3D"_blank">[email-masked]</a>&gt;<o:p></o:p></p><p>An: =
&quot;Michael Salter&quot; &lt;<a =
href=3D"mailto:[email-masked]" =
target=3D"_blank">[email-masked]</a>&gt;, &quot;<a =
href=3D"mailto:[email-masked]" =
target=3D"_blank">[email-masked]</a>&quot; &lt;<a =
href=3D"mailto:[email-masked]" =
target=3D"_blank">[email-masked]</a>&gt;<o:p></o:p></p><p>&nbsp;<=
o:p></o:p></p><p>&nbsp;<o:p></o:p></p><p>&nbsp;<o:p></o:p></p><div><div><=
p class=3DMsoNormal><span style=3D'color:black'>Regarding these =
contraptions, there is a third way. I've mentioned it to M before....one =
can gut the old relay and rebuild its internals with new, modern, =
relays. I've done two or three. The first because my original had gone =
into terminal decay and the others because I'd bought clapped out =
originals at a boot fair. Anyhow, the first one's been in the car for =
some years now and works fine. The others are in one of the &quot;boxes =
of useful things I may need one day&quot;. I've done the same to =
overdrive relays. By the way, I don't claim to be the first person to =
have done this!!<o:p></o:p></span></p></div><div><p =
class=3DMsoNormal><span =
style=3D'color:black'>Simon<o:p></o:p></span></p></div><div><p =
class=3DMsoNormal><span =
style=3D'font-size:9.0pt;font-family:"Arial",sans-serif;color:black'>&nbs=
p;<o:p></o:p></span></p></div><div class=3DMsoNormal align=3Dcenter =
style=3D'text-align:center'><span =
style=3D'font-size:9.0pt;font-family:"Arial",sans-serif;color:black'><hr =
size=3D2 width=3D"98%" align=3Dcenter></span></div><div><p =
class=3DMsoNormal><strong><span =
style=3D'font-size:11.0pt;font-family:"Calibri",sans-serif;color:black'>F=
rom:</span></strong><span =
style=3D'font-size:11.0pt;font-family:"Calibri",sans-serif;color:black'> =
Healeys &lt;<a href=3D"mailto:[email-masked]" =
target=3D"_blank">[email-masked]</a>&gt; on behalf of =
Michael Salter &lt;<a href=3D"mailto:[email-masked]" =
target=3D"_blank">[email-masked]</a>&gt;<br><strong><span =
style=3D'font-family:"Calibri",sans-serif'>Sent:</span></strong> 20 =
March 2026 16:23<br><strong><span =
style=3D'font-family:"Calibri",sans-serif'>To:</span></strong> <a =
href=3D"mailto:[email-masked]" =
target=3D"_blank">[email-masked]</a> &lt;<a =
href=3D"mailto:[email-masked]" =
target=3D"_blank">[email-masked]</a>&gt;<br><strong><span =
style=3D'font-family:"Calibri",sans-serif'>Subject:</span></strong> =
[Healeys] Replacement Turn Signal Relay.</span><span =
style=3D'font-size:9.0pt;font-family:"Arial",sans-serif;color:black'> =
<o:p></o:p></span></p><div><p class=3DMsoNormal><span =
style=3D'font-size:9.0pt;font-family:"Arial",sans-serif;color:black'>&nbs=
p;<o:p></o:p></span></p></div></div><div><div><div><div><p =
class=3DMsoNormal><span =
style=3D'font-family:"Arial",sans-serif;color:black'>All Big Healeys =
prior to the later Phase 2 BJ8 use a Lusas 33117 relay for the turn =
signals. This relay connects the appropriate&nbsp;lamps to the turn =
signal flasher unit, overriding&nbsp;the brake light switch on =
turns.<o:p></o:p></span></p></div><div><p class=3DMsoNormal><span =
style=3D'font-family:"Arial",sans-serif;color:black'>These Lucas relays =
were a very primitive&nbsp;(by today's standards) but very robust unit =
and could withstand a short circuit as often happens with the glass =
lens&nbsp;type&nbsp;594&nbsp;turn/side/brake lamps used on these models =
at least until the fuse blew.<o:p></o:p></span></p></div><div><p =
class=3DMsoNormal><span =
style=3D'font-family:"Arial",sans-serif;color:black'>Within these lamps =
it is very easy to produce a short to =
ground.<o:p></o:p></span></p></div><div><p class=3DMsoNormal><span =
style=3D'font-family:"Arial",sans-serif;color:black'>Over the last few =
years replacements for these relays have been provided,&nbsp;under the =
Lucas&nbsp;name and the same 33117 part number, which have been =
completely redesigned and incorporate 2 modern G2R-1-E =
relays.&nbsp;<o:p></o:p></span></p></div><div><p class=3DMsoNormal><span =
style=3D'font-family:"Arial",sans-serif;color:black'>I have =
purchased&nbsp;2 of these modern style&nbsp;relays and both have failed =
because the&nbsp; G2R-1-E relay relays don't seem to be anywhere near as =
robust as the originals and fail before the 35 amp fuse can protect =
them.&nbsp; &nbsp;<o:p></o:p></span></p></div><div><p =
class=3DMsoNormal><span =
style=3D'font-family:"Arial",sans-serif;color:black'>So, a word of =
caution, if you are using one of these (improved) cheapo repo turn =
signal relays, be very careful to avoid short circuits in the =
turn/brake/side lamps.<o:p></o:p></span></p></div><div><p =
class=3DMsoNormal><span =
style=3D'font-family:"Arial",sans-serif;color:black'>The =
attached&nbsp;pics are of the original type and the circuit board from =
the &quot;improved&quot; replacement.<o:p></o:p></span></p></div><div><p =
class=3DMsoNormal><span =
style=3D'font-family:"Arial",sans-serif;color:black'>&nbsp;<o:p></o:p></s=
pan></p></div><div><p class=3DMsoNormal><span =
style=3D'font-family:"Arial",sans-serif;color:black'>M&nbsp;<o:p></o:p></=
span></p></div><div><p class=3DMsoNormal =
style=3D'margin-bottom:12.0pt'><span =
style=3D'font-family:"Arial",sans-serif;color:black'><img border=3D0 =
width=3D499 height=3D466 style=3D'width:5.2in;height:4.85in' =
id=3D"Picture_x0020_2" =
src=3D"cid:[email-masked]"></span><span =
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