Heavy-duty headlight connectors?
 

I want to do the DIY headlight upgrade, and was thinking.. Does someone make a headlight connector wired with heavier gauge wire? I'm not sure what gauge is in it currently, but I guess I'm just one for a little over-engineering.

Re: Heavy-duty headlight connectors?
 

There are lots of options for headlight upgrades. One of the most common upgrades is to simply install halogen sealed beam bulbs. H6024 bulbs, they are inexpensive ($8 - $12 each), and the existing wiring can handle it.

To over-engineer, it is most effective to worry about the length of the wire more than the gauge of the wire, and people do that with the relay mod. Using that method you can power the headlights directly from the battery, which is near the headlights, and just use the existing wiring from the headlight switch to turn on the relays. I have already upgraded my bulbs to the H6024, and have it on my to-do list to install a relay harness such as this one:
https://www.amazon.com/dp/B00XXOC9Z4

There is a risk with this in there are more things to fail, fuses could go out, relays could fail, etc. leaving you with no way to see as you're speeding down a dark winding highway. I've considered maybe adding a rectifier diode between the wire that powers the relay and the wire that goes to the headlights, so if the fuse or relay fails, the lights would not go out completely, they would just dim.

Re: Heavy-duty headlight connectors?
 

Forget about that Chinese junk-if you need OEM quality Delphi headlight connectors and terminals-I have them. The "ceramic" connectors you see all over the Internet are from China and are about as strong as dried toothpaste and-they are the worst copy of a 59-series terminal that they may not even fit on a quality headlight! The wiring is NOT rated for underhood use (j1128 is the correct specification for underhood wiring) and the copper strands are wound with tin filler metals which weaken the wiring-again a product of China. Those relay kits are cheap indeed and for a reason. I have Pre-terminated and soldered Packard 59-series terminals pigtails for 3-prong 6024 headlights for $12 shipped. If you need a high quality relay kit PM me for details....I have many options.

Re: Heavy-duty headlight connectors?
 

Well there you go. I knew there was a reason I had not ordered the Chinese harness yet and was just thinking about it.

Re: Heavy-duty headlight connectors?
 

I just don't care for anything overseas-nothing is built with any regards to quality.

Re: Heavy-duty headlight connectors?
 

Gmachinz, what wire do you recommend for underhood wiring? GXL? SXL? Do you always have to look for "j1128" or can you rely on a label/type like "GXL"?

Re: Heavy-duty headlight connectors?
 

SXL or TXL is what you want-GPT has lower heat rating so it's not j1128 spec.

Re: Heavy-duty headlight connectors?
 

gmachinz - What gauge wire are you using for the headlight pigtails?
I am interested in a relay kit. I'll send you a PM.

Re: Heavy-duty headlight connectors?
 

I use 14ga SXL wiring and sealed relays/fuses.

Re: Heavy-duty headlight connectors?
 

Reply PM sent.

Re: Heavy-duty headlight connectors?
 

gmachinz,
Sent you a couple of PM's. Sent payment for a harness. Just checking to make sure it was received. Thanks!

Re: Heavy-duty headlight connectors?
 

Oh yes-forgot to reply here lol-I got your info-I'm finishing yours up today-should be ready to go out today as well!

Re: Heavy-duty headlight connectors?
 

Thanks, Gmachinz.. I'm looking for them.

Re: Heavy-duty headlight connectors?
 

So.. I'm pretty stoked! Got the harness from Harnessworx and Gmachinz, and this thing looks GREAT! I can't wait to get it installed!!

Re: Heavy-duty headlight connectors?
 

You'll love it! At about a 2V increase you should have about 20% more light output over the stock setup regardless of bulb type. Post some before/after pics if you can!

Re: Heavy-duty headlight connectors?
 

I'm following along as I am also going to get an upgrade kit from Gmachinz.

Please post up some before and after pics!