Extending HID high voltage leads

[OzzieDoc]

I've modded an old "5 million cp" using an eBay HID H3 kit and was pleased with the results. I would now like to try the same with some driving lights I have. However the kit I used had fairly short leads from the ballast to the bulb and I would like to extend them so as to place the ballast out of harms way. Is it as simple as cutting them and inserting good quality cable soldered in place and perhaps double heatshrinked and siliconed or is there something extra special required because of the voltage requirements. I would be adding less than 12 inches. Thanks.
Ozziedoc

 

[SFG2Lman]

you could always try spark plug wires as they are also designed for high voltage over a bit of a distance, just a thought, not by any means the only solution

 

[alpg88]

spark plugs wires.

i did that too to my 6m cp light, loved the result, but it just $@#%& had to fell off the boat and drown.

 

[XeRay]

I've modded an old "5 million cp" using an eBay HID H3 kit and was pleased with the results. I would now like to try the same with some driving lights I have. However the kit I used had fairly short leads from the ballast to the bulb and I would like to extend them so as to place the ballast out of harms way. Is it as simple as cutting them and inserting good quality cable soldered in place and perhaps double heatshrinked and siliconed or is there something extra special required because of the voltage requirements. I would be adding less than 12 inches. Thanks.
Ozziedoc

Where is the igniter located, in the ballast or in the cable to the bulb? The maximum cable distance from the igniter is about 3 feet. Also max voltage 20-30,000 volts so the insulation must be done correctly.

 

[OzzieDoc]

In the ballast. The existing cable is less than 12 inches so even if I add another 12 inches it's still less than 2 feet. Spark plug wires sound interesting. Is soldering adequate and is double layer heatshrink then silicone enough insulation?

 

[XeRay]

In the ballast. The existing cable is less than 12 inches so even if I add another 12 inches it's still less than 2 feet. Spark plug wires sound interesting. Is soldering adequate and is double layer heatshrink then silicone enough insulation?

You need very good insulation between the 2 wires to prevent arcing, I would use rubber tape.

 

[BVH]

Or buy 25KV rated, 22 or 20 ga silicone jacketed wire.

 

[OzzieDoc]

I just noticed that some of the eBay vendors mention extension leads just for this purpose though I can't actually find them offered for sale separately. Will keep looking before I try it myself.

 

[Flashanator]

Just Curious as to how long the high voltage lasts for in a typical automotive HID bulb? I assume a few seconds?

 

[BVH]

I would guess it's in fractions of a second.

 

[Norm]

Stagger the joins, less likely to arc over that way.
Norm

 

[Patriot]

From what I've read, thanks to BVH earlier pointing me to the wiring info, with 25KV 22g silicone wiring, no other precautions need to be taken. Get a few feet of that to splice in and your set.