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Unread 07-29-2012, 04:03 PM   #1
mudsweatNgearz
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Head light relay mod write up with pics...WOW what a difference

High everyone,

I am going to attempt to document my method of the headlight mod using relays. This is my first write up ever and I don't pretend to be any kind of a mechanic or expert of any kind. I am sure I could have done some things better but like I said I am a total amature at this stuff and did the best I could. I was amazed at the before and after pictures of the difference in brightness.
As we all know the factory headlight system leaves much to be desired. Using under sized wiring and running all that juice up through the switch is well, just plain cheezy to say the least. I can thank this forum for the idea and the guidance to complete this mod.

To start out I used this diagram:



What you will need:

2 30 amp 12v dc relays.(one for low beam and one for high beam)..local auto parts store
A bunch of 12 ga wire of a few different colors
2 inline fuses 12 ga with 25 amp fuses
various connectors and such

I started out by cutting the wire at factory headlight connectors. I took the pins out of the connectors and cleaned them all up. Then I soldered the 12 ga wire to the factory pins and reinserted them in the connectors (I didn't want any of the factory 18 or 20 ga wire or whatever it is anywhere in the circuit). I would suggest going to the auto parts store and getting new connectors. They are an off the shelf item and don't cost much.

Use a pick or a connector disassembly tool to get the pins out of the connector.



I cleaned them all up and soldered my 12 ga wire directly to the pins.



I then followed up with 3 layers of shrink tube and reinserted the pins back into the connector. Be sure the locking tabs are sticking up plenty far and listen for the click when you stick the pin back into the connector, gently tug back out on the wire to confirm a positive lock. I also coated all connections with dielectric grease.





Next I soldered in a T splice to run the other headlight and ran the loom behind the grill.



Using a pick I split the wire and inserted the other wire into the split then twisted them togeather. After soldering I used plenty of electrical tape, then zip tied over the electrical tape to keep the tape from ever unravelling and finally it will go into loom.

Next I mounted the relays on the inside of the wheel well behind the driver headlight.



I used crimp on female spade connectors to connect to the relay pins but I should have used relay connectors designed for this purpose (I will redo sometime with a solder on connector sometime).

I then ran power from my battery to the relays. I used two seperate power feeds but looking back I only needed one power feed wire then I could have soldered in a T splice just before the relays to run both relays...oh well, lots of lessons learned during this project.

On each of the power feed wires I soldered in a 12 ga 25 amp fuse holder. Be sure to get a good water resistant one with the push on cap like this one.



Loom and ziptie everything up and enjoy your much more reliable and efficient lights!!
On the before and aft pics the left headlight looks brighter because I am parked crooked in my garage and I am pretty close to the garage door.

Before:

After: Not only are they much brighter notice how much whiter the light is....can't wait for it to get dark and go for a drive... hehe


And while I am at it just for fun my white face gauge mod:








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Unread 07-29-2012, 05:22 PM   #2
Michaelgoesrawr
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What wires from the headlight switch did you use to power the relays?
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Unread 07-29-2012, 05:52 PM   #3
TheSmanman
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Very nice job man! I like the white face gauge mod too. Where did you get them from.
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Unread 07-29-2012, 05:59 PM   #4
Luuca
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A few Questions:

These are stock, sealed headlamps?
What was your total time on this project?
Do you have more pictures of the overall under-hood appearance of the wiring? How much clutter does this add?
You mention using water-tight in-line fuses and yet your connections at the relays are exposed. Any solutions to this issue?
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Unread 07-29-2012, 07:15 PM   #5
mudsweatNgearz
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Quote:
Originally Posted by Michaelgoesrawr View Post
What wires from the headlight switch did you use to power the relays?
I cut the wires at the connector on the back of the headlight...these wires will power your relays for the switching action. You will only use the wires from one headlight. I believe the white one is high beam and it goes to one relay. The green one is low beam and it will switch the low beam relay. Black is ground.
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Unread 07-29-2012, 07:19 PM   #6
mudsweatNgearz
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Quote:
Originally Posted by TheSmanman View Post
Very nice job man! I like the white face gauge mod too. Where did you get them from.
Whitefacegauge.com. They gave VERY good service. They have a great website with good detailed instructions. Kit was like $25 shipped. I also bought some flourescent orange paint for the needles from a different outfit. The paint is like $8 for a teeny little jar but I had plenty left over. I used a toothpick to apply the paint...worked great. probably the best mod I have done so far as far as bang for the buck.
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Unread 07-29-2012, 07:31 PM   #7
mudsweatNgearz
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Quote:
Originally Posted by Luuca View Post
A few Questions:

These are stock, sealed headlamps?
What was your total time on this project?
Do you have more pictures of the overall under-hood appearance of the wiring? How much clutter does this add?
You mention using water-tight in-line fuses and yet your connections at the relays are exposed. Any solutions to this issue?
These are stock, sealed headlamps?
Yes these are the stock sealed beams. I used the existing lights that were in there...really brought em to life.

What was your total time on this project?
Total time was a complete day..prolly around 8 hrs. I am sure it could be done much faster but I had the attitude of just tinkering and having fun all while learning.

Do you have more pictures of the overall under-hood appearance of the wiring? How much clutter does this add?
Yes I can snap more pics if you want. Does not add much clutter for what you get. Well worth it and if you do a good job and do not rush it looks pretty cool. I was out of black loom and the auto parts store only had blue. I was not sure if I was going to like the blue but now that it is all done I must say it is not bad at all.

You mention using water-tight in-line fuses and yet your connections at the relays are exposed. Any solutions to this issue?
As I stated in the write up you can buy relay connector plugs and looking back this is what I should have done. I will upgrade this in the near future and update the mod.
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Unread 07-29-2012, 07:40 PM   #8
HurricaneRZA
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I've got a similar setup.

If you think it's an improvement now wait 'til you throw in an E-code H4 conversion and higher wattage bulbs!(Assuming you plan on upgrading the headlamps from the sealed style). My lights out perform most aftermarket HID kits that I see on the road in terms of usable light and the E-code are damn good at putting the light where I need it and not in people's faces...

Only differences are that I separated mine from the alternator completely (means I'm getting about 12v steady as opposed to 14v-16v from the alternator-mine jumps around quite a bit sometimes-that's mostly because I'm just picky about light flicker though...) And that I used a pre-made relay harness (got it for free)... Same setup as yours but I need to clean up the wires (it's a one size fits all so many wires are far too long for the jeep, I coiled them and zip tied them out-of-the-way for a rainy day.)
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Unread 07-29-2012, 08:05 PM   #9
GunHo198
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Unread 07-29-2012, 08:06 PM   #10
mxmike480
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Nice write up. I need to do my wrangler, but my Cherokee came out with some nice lights. I bought a wiring harness from a site online that was complete with relays & was plug & play, no need to cut or splice anything. I paid around $18.http://www.eautoworks.com/Putco-H4--...s-PRD7540.aspx
Looks like they are a bit more now, but it is a nice kit.
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Unread 07-29-2012, 08:28 PM   #11
Mywrangler94
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so you can use that wireing harness to upgrade the headlights on your 88 and my 94 Mike?
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Unread 07-29-2012, 09:34 PM   #12
mudsweatNgearz
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Someone wanted more pictures of the overall job:

I am also running my KC lights from the battery to a relay so I am starting to get a bit of a mess going. I will be looking into a fused terminal strip or a breaker box mounted on the firewall to clean up the mass of wires coming off of the batt. I am also looking into a relay block to clean up the relays as well





The blue loom going around behind the engine carries the main power feed to the relays located on driver front wheel well.



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Unread 07-30-2012, 12:00 AM   #13
castorriver
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That looks pretty tight. Nice job.
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Unread 07-30-2012, 06:06 AM   #14
mudsweatNgearz
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Quote:
Originally Posted by castorriver View Post
That looks pretty tight. Nice job.
Thanks man, It was a good learning experience for me.
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Unread 07-30-2012, 06:25 AM   #15
johninmichigan
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I'm in the procurement process now on my Headlight relay project on my CJ7. I found some nice distribution blocks at pick a part on 80 - 90's GM trucks. They are open studs but a high plastic wall around so you don't get accidental grounds to tools and such. I also found some nice heavy relays on S-10's with AC. Yours looks like it came out very nice. I hope mine works out as well. John
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electrical , h4 , head light , headlight upgrade , relay

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