Headlight relay wiring
Thread Starter
Team Owner
Joined: Oct 2004
Posts: 23,831
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From: Springfield MO
St. Jude Donor '07
Headlight relay wiring
Those of you who have installed relays in your headlight system - where did you tap into the wires from the switch to the lights? I assume the wires are in that taped bundle running along the upper inside edge of the driver-side fender.
Team Owner
Joined: Jul 1999
Posts: 65,492
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From: Orange Park Florida
I have never actually DONE it, but well yes, those wires...you need determine which is which he/lo/blinker/side etc.....find the two to the hi/lo....and put them to the relay coils....hot side, other to ground....and then heavy up the wiring to the lights themselves, and the main power source off the horn terminal, should be good enough...
assuming you have a decent wire to the horn term from the alt output stud....
assuming you have a decent wire to the horn term from the alt output stud....
Le Mans Master
Joined: Jan 2006
Posts: 9,192
Likes: 27
From: Boca Raton Florida
Batnman, this is the drawing I used. The black, green and tan wires run from the firewall connector thru the bundle along the drivers fender to the headlights. If your going to do this, cut the wires there by the alternator, use the part coming from the firewall to trigger the relays and the part going to the lights on the contacts for the relay
Thread Starter
Team Owner
Joined: Oct 2004
Posts: 23,831
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From: Springfield MO
St. Jude Donor '07
That's where I was going to tap in, because that's where I'm installing my fuse/relay box (a really nice underhood piece salvaged from a Lincoln Mk. VIII - aren't they useful cars? 
). I didn't want to start hacking in there until I was sure that was the location of the wires. I'll probably run new, heavier wiring to the headlights - I have new high-temp sockets for my H4s, and my H1s will have 100w bulbs.
I finally managed to track down a single E-code 5.75" Hella H1 housing. Damned thing cost me as much as the other H1 and the two H4s combined. Since the introduction of the US-spec Hella housings, the E-code stuff has become hard to find.
). I didn't want to start hacking in there until I was sure that was the location of the wires. I'll probably run new, heavier wiring to the headlights - I have new high-temp sockets for my H4s, and my H1s will have 100w bulbs.I finally managed to track down a single E-code 5.75" Hella H1 housing. Damned thing cost me as much as the other H1 and the two H4s combined. Since the introduction of the US-spec Hella housings, the E-code stuff has become hard to find.
Melting Slicks
Joined: Jan 2006
Posts: 3,028
Likes: 2
From: North NJ
That's where I was going to tap in, because that's where I'm installing my fuse/relay box (a really nice underhood piece salvaged from a Lincoln Mk. VIII - aren't they useful cars? ). I didn't want to start hacking in there until I was sure that was the location of the wires. I'll probably run new, heavier wiring to the headlights - I have new high-temp sockets for my H4s, and my H1s will have 100w bulbs.
I finally managed to track down a single E-code 5.75" Hella H1 housing. Damned thing cost me as much as the other H1 and the two H4s combined. Since the introduction of the US-spec Hella housings, the E-code stuff has become hard to find.
). I didn't want to start hacking in there until I was sure that was the location of the wires. I'll probably run new, heavier wiring to the headlights - I have new high-temp sockets for my H4s, and my H1s will have 100w bulbs.I finally managed to track down a single E-code 5.75" Hella H1 housing. Damned thing cost me as much as the other H1 and the two H4s combined. Since the introduction of the US-spec Hella housings, the E-code stuff has become hard to find.
And I'd love to see pics of your progress of installing the relays, fuse box and headlights. Souds like you'll be able to see a tick on a deer a mile down the road.
Advanced
Joined: Mar 2007
Posts: 91
Likes: 0
From: London, UK
That's where I was going to tap in, because that's where I'm installing my fuse/relay box (a really nice underhood piece salvaged from a Lincoln Mk. VIII - aren't they useful cars? ). I didn't want to start hacking in there until I was sure that was the location of the wires. I'll probably run new, heavier wiring to the headlights - I have new high-temp sockets for my H4s, and my H1s will have 100w bulbs.
I finally managed to track down a single E-code 5.75" Hella H1 housing. Damned thing cost me as much as the other H1 and the two H4s combined. Since the introduction of the US-spec Hella housings, the E-code stuff has become hard to find.
). I didn't want to start hacking in there until I was sure that was the location of the wires. I'll probably run new, heavier wiring to the headlights - I have new high-temp sockets for my H4s, and my H1s will have 100w bulbs.I finally managed to track down a single E-code 5.75" Hella H1 housing. Damned thing cost me as much as the other H1 and the two H4s combined. Since the introduction of the US-spec Hella housings, the E-code stuff has become hard to find.
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Thread Starter
Team Owner
Joined: Oct 2004
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From: Springfield MO
St. Jude Donor '07
Pics. The box has a shield that clips to the bottom that isn't pictured here.
Pro
Joined: Nov 2000
Posts: 594
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From: Tucson AZ
Here is the way I came up with to power my headlight relay sytem. This alternator harness is made from 8ga wire and connects directly to the output of the alternator. The circuit is protected by a 40amp maxifuse and connects to the main relay harness via a 75amp powerpole connector.
Here is a look at the alternator connection. The tap here is where the old alternator wire goes.
Craig
Here is a look at the alternator connection. The tap here is where the old alternator wire goes.
Craig
