[83GMCK2500]

Last weekend the less-than-temporary headlamp harness was created. With the help of my good friend we removed the OEM harnesses, dissected the BS headlight wiring, and re-created them using all 12-gauge wiring. During this time wiring for fog lights and driving lights were added. We used 4 heavy duty Bosch relays with weatherpack connectors to power the circuits, lowbeam, highbeam, driving and fog lights. The highbeam switch will trigger low, high and driving lights for a 6-hi combination. The fogs are independently switched. Everything is fully soldered and weatherproofed.



After dissection


All new gauge leads.


Wiring

Laying out relay sockets

Yellow leads on relays will be triggers, here is the highbeam trigger with diodes for triggering low & driving lights.

One of the completed relay socket sets, this one had orange trigger wires.




Relay mounting under the ECM


Completed harness



After adding the harness


***Disclaimer, some of these pictures were taken by me, the rest by my friend. This upgrade was simultaneously performed on two trucks, his and mine. The text above has been edited but the body of it are his words. (I'm being lazy and copying from his thread, elsewhere.)