santro 2011, upgrade queries

I own a santro xing gls 2011 model, and i frequently drive through ghat section as well as in highways (approx 300 - 400km in total / week). I would like some upgradation since am not hapy with the stock parts.  

Please help me with my below queries.

1. What would be the appropriate amp/watt measurement for relay and fuse, if i upgrade my stock bubs to 100/130w? (I usually drive thorugh ghats and hence requires higher wattage)
2. What would be the appropriate amp/watt measurement for relay and fuse, if i install Hella 550ff (h3 55w bulbs) auxilary lamps?
3. Currently the stock exide battery of 40ah. Will i require to upgrade to higher power battery/change the alternator if i run the following parts together 

•  
  • 2 h4 100/130w bulbs
  • 2 h3 55w fog lights
  • 2 Hella 550ff auxilary lamps (h3 55w)
  • Sony explode ICE with normal speakers (no amps or woofers)
  • Aircondition

Sanju, my suggestion is the following:

1. As you plan for auxilary lamps, 130/100 is not really necessary. That is because when you want the lights only for your car to be seen, ie where the road is sufficiently lit up, you will have to use the 100 watt low beam which is just not required. Also, you would have upgraded the fogs which also cant be used in such conditions. So, I feel 100/90 will make a better option. Also, the heat generated is comparatively less so you dont have to worry about faded or smoked reflectors.

2. For the auxilary lamps, a combined load comes to ~110watts. So, 110 watts at 12 volts will approximately draw around 9-10 amps of current. Go for a 15 amp relay on the safer side to avoid burn outs under prolonged usage. The usual headlamp relays are rated at 30Amps @ 12 volts. So it is fine. 

3. Regading fog lamps, are you changing the bulbs to 55 watt or the entire fog lamp unit? Because, the Fogs are usually 35 watt and I think it is the same for the santro or even less. Due to the small sized construction, I am doubtful that the assembly will withstand the extra heat generated. So, keep this your last priority. 

4. If you upgrade all the lights as said above, it not only requires a better battery but also a higher charging rate. I would suggest you to upgrade one at a time. First change the headlamps, followed by auxilary lamps and finaly the fogs. I have found that a combination of Bright Fogs and a 100/90 main light to be more than sufficient. So, observe the change each time and only then proceed. The Hellas do a good job when focussed. 

Btw, what lights are you currently using? If it is the stock, then 100/90 will make a considerable difference. Hence, upgrade step-by-step.

Thanks sanshrinand. The info was really useful

1. I currently use stock 55/60w and there were many incidents where i have escaped just out of luck. So after searching and reading through many articles regarding headlamp upgrade, i too feel 90/100w would be the better option. Along with that i think hella 30Amp relay would be just fine. I would let you know my opinion once i do the upgradation.
2. If my understanding is correct, i need to go for separate relays. One dual lamp relay(30Amp) for headligh and one  dual lamp relay(20Amp) for auxilary lamps.
3. The fog light was purchased along with the car from hyundai, but the spread and illumination is really poor. Its like the fog lights does not exist at all. What would be the best option of upgrading the fog lamp? One of my friend said that even if i replace the bulb in fog unit, it will still be useless since the company fog reflector is really poor. If so do i need to replace the entire fog unit? 
4. I am looking at option of upgrading my battery to Amron pro (looking somewhere between 45AH - 60 AH). But i dont know if the battery size will hinder the upgrade. Though i am going to make the battery upgrade as the last step.

This would me my modification plan

• Change to 90/100w along with 30A relay
• Install Hella 550ff along with 20A relay
• Upgrade battery to 45AH or above which would fit without any mod.

• Upgraded my lights to plilips rally 100/90. Light seems brighter but since its day time cannot tell the effect. Also i purchased philips wrirng kit (30A philips relay + fuse + wiring + ceramic holder), wiring can withstand fire as well as its especially made for 130/100 bulbs. So is more reliable.
• About fog lamps, technician told not to upgrade since it may involve wire changes and take more time. So advised me not to change though hella h3 100w are available for fog lights.
• For hella lamps, they only has the lamp + wiring kit, the L type clamb i need to fix separately. I have to enquire about that. Will keep you posted.
• For guys from cochin kerala, i bought the parts from hella authorised shop (Roots auto world, SN jn, Refinery road, Thripunithara. Ask for Ashraf, 04842779790)

I have tested my 100/90w lights last night, and the beam was excellent. Also i have adjusted the left headlamps to go outside the road, to see pedestrians and 2wheelers. Believe me it really helps. 

To adjust headlight in santro, there are two screws on left top(LT) and right bottom(RB), tight the  RB screws while loosen the LT screws, this will make headlight assembly unit align to left, but dont do it more than 5 turns. Gurus can you confirm whether this is the right way to adjust headlights.  

Just want to share another experience i had yesterday. I called an amron authorised dealer and enquired him about upgradation of my battery. Not only he denied it, he said that santro comes with 35AH battery and you shouldnt go beyond that since it will affect the wiring and alternator. I had hard time telling him that 2011 model santro gls comes with company installed 40AH battery. Its written in the manual itself.

Anyway after him trying to convince me to go for 35AH battery, i asked him one question "if i have lots of high wattage bulbs, amplifiers and woofers of higher wattage, plus lot of cosmetics like underbody neon lights then will the 35AH be enough?". With that he told me that i can go for 45AH battery after modfiying the tray and other wiring. 

Now my question is do i really need to change/modify so many things just to upgrade my battery?

For adjusting the beam, there are complex scales and measurement systems provided by the manufacturer. For a rough idea, on an open road, with the headlamp leveller in the highest position(0), the low beam must fall on the road, with the \_\_ cutoff pattern visible clearly. The _ _ portion will fall on the road, while the \ \ angle is used to illuminate the side, without causing glare to the opposite driver. This will ensure that the high-beam will be at the right point, without being too high or too low. Some people have their lights aimed high, and also towards the right. This affects both his visibility as well as the oncoming car. 

Now I think as you are satisified with the Rallys, you can think of just a pair of auxillary lights and use them only when additional lighting is required. After installing, use the lights and check. If the battery runs weak, then you will require additional current. If so, then you can use a 45Ah battery. It will be better in such situations. Just ensure it will fit in the tray. Wiring odifications and tray modifications will require good skill and if not, the job can be ruined.

Rallys are running fine without any issues. Feeling great about the decision i made. No probs with batteries also. 

To those who use high wattage bulb i have one advice, if the road is well illuminated use the low beam, if you really cant see the road ahead then switch to high beam. Also be kind to dip for oncoming drivers no matter whether they care to dip or not, after all its your life and car at stake here.

@Sankalp: Regarding auxiliary lights, whats the best way to fit without having a nudge bar or drilling holes. I have read online that some L type brackets can help, but dont have any details on that. Can you help me with details of  where to buy, how to make it rigid (shaking lights will be bad for visibility), where exactly to fit etc. 

I dont want the nudge bar since it would affect the car crumble zone, and dont like the idead of drilling holes. So would like to know if there exists any other solution.

There is an option of custom designed brackets. Drilling holes in bumpers is not a correct way, as the bumper is a plastic part and it wont hold good in the longrun. Check out if there is any chassis mounting point behind the bumper. You can get a bracket designed by any fabricator such that it can be screwed or bolted onto the chassis frame and then protuded outside the bumper. This will give you a rigid mount.