Smoking wire! -
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Unread 07-09-2011, 05:24 PM   #1
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1980 CJ7 
Join Date: Mar 2010
Location: Tooele,, Utah
Posts: 26
Smoking wire!

Alright JF, Ive gota duzy here with my '80 Cj7
I installed a set of new Delta Hyperwhites that run the H4 bulbs and at 60/55
watts. After fixing a faulty ground, i left the headlights on to admire them. I
got back in the cab and the red w/ white wire was smoking and melting the
plastic on the harness for the headlight switch! It only smokes when I turn on
my brights though. After examining my diagram, i found that its my *foot dimmer switch feed*.so my questions are, is my dimmer switch faulty? or do i need bigger wire to make up for the new headlights? and how do I run relays for my new deltas?

thanks in advance!

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Unread 07-09-2011, 05:37 PM   #2
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1977 CJ7 
Join Date: Mar 2011
Location: , Northern Arizona
Posts: 2,903
You're pulling too many amps through the switch. Consider strongly a headlight relay under the hood and running heavier gauge wire for both 12V feed through the relay AND ground back to the battery or at least a ground buss. I DON'T KNOW THE FORMULA, but I'd run 10 gauge wire considering you're pulling about 700 watts.
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Unread 07-09-2011, 05:43 PM   #3
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1980 CJ7 
Join Date: Mar 2010
Location: Tooele,, Utah
Posts: 26

went out and checked again. This time , no smoke and no heat on the said wire. Now both high beams work and only left low beam works.
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Unread 07-09-2011, 06:27 PM   #4
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1985 CJ7 
Join Date: Sep 2008
Location: White Springs, Florida
Posts: 8,879
Have a look at this thread. It discusses the use of relays. I didn't read through the whole thing, but knowing Jeephammer, he probably explains in detail how to install. DON'T run your headlights the way you have them wired. You could end up burning down your Jeep!
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Unread 07-10-2011, 07:13 AM   #5
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1984 CJ7 
Join Date: Jan 2009
Location: Cape Cod
Posts: 809
The wiring upgrade is a must. Look at the above link. Once you get all the parts on hand it isn't as confusing to do.
I did this a while back and the difference is unbelievable.
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