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Old 10-07-2013, 07:59 PM   #2
Sharps40
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Join Date: Oct 2012
Location: here
Posts: 2,408
Re: John Lee's Halogen Headlight with Relay's Upgrade

Rather than fiddle with fuzes, I installed a 30 amp self resetting breaker to protect the circuit. Mounted to the radiator shroud and ready to wire up.



A single 12g wire (top) taps power directly from the connections to the + terminal of the battery on the radiator shroud.

A pair of 12g wires (bottom) out will send power to the High and Low beam relays. Now all the high amp load on the switches (factory set up) is transferred direct from battery to relay. The switches should now be operating at a single amp or so, just enough to trigger the relays.



Breaker installed and the two relays. High beam relay (green wire) to the left, Low beam relay (brown wire) to the right. All the new wires plumbed in, crimped and soldered connectors and nicely wrapped to provide protection/better looks. Both relays are grounded to the radiator shroud up at the original ground point for the horn relay.



Finishing up the hookups at the headlights. New sealed beam halogens installed in the buckets. New high temp connectors installed and connected to the relays output terminals.



These are the grounds for the individual headlights. One each left and right in the radiator shroud. Once the left and right windscreens are reinstalled, they will be invisible.



After double checking all the connections and tracing the wires one last time, I apply power. Zowie, 12.5 volts at the light sockets. Almost 2 volts gained at the lights where needed. Should be blinding for deer this fall!



Oh yeah, Way brighter on low beam than the sealed beams ever were on high.



Waitin for darkness, gotta aim em and test drive!
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