Ace

Finally got around to re-wiring the headlights, and glad I did. They were noticeably brighter with just the new wiring/relays. So I decided why not go the whole way and got some new HO bulbs as well and could not believe the improvement. This is a must-do upgrade.

I went for a couple minor variations, just to be on cheapie side. Used some old style AGC-type fuse holders and fuses on the 12v input feeds to the relays, just because I already had them onhand. I also fabricated individual slip-on lugs for the bulb connections out of one inch peices of brass tubing. Soldered every lug, sixteen in all, I believe as well as the fuse lugs/connectors. Should provide maximum contact/reliability.

They look to be throwing out at least double the candlepower they were before.

Rampage1967

I took the relays & harness off a caravan i was junking for mine. (I had done this on the van before) The truck already had HO sealed beams on it.
I've never seen headlamps shine that bright white. With the wiring set up to light all four filaments on hi beam it really lights up the road & the low beams are actually useful. Now all Now all I need is e-specs with 80 watt low beams.

Figlos

I have a 90 Dodge 5.9. I measured the voltage at the headlights with the engine running. I get 14.1 volts. The voltage across the battery is ~14.9 volts. I am questioning if it is a good idea for me to install relays if I am getting this kind of voltage at the headlights.

4x4dually

Make sure you are measuing voltage at the headlights with the headlights turn on. (ie. don't unplug them and then measure). You won't see a noticable votlage drop until some current is being pulled through the wires. If it is still 14.1 with them on, I wouldn't worry about it. .8 volts ain't enought to worry with to me.

Figlos

Thats what I did. I measured the voltage with the engine running and headlights on.

Rampage1967

Check the voltage drop on that ridiculously small ground wire. it'll surprise you. It doesn't matter which side of the bulb the voltage drop is on. That wire looks like about a 20 gauge wire.

janb

What is an economical sourcefor relays? (and ez to get)

It does get a embarassing driving down the road with the headlights blinking and shutting off. Seems to be worse on blind corners...(and dark rainy nights)

Redleg

While you're at it, replace the headlight switch if you haven't, if the lights are cutting out. Good tip though, i just so happen to have a Camry to salvage from... wonder how heavy wire they used.

wannadiesel

I got mine from www.partsexpress.com.

BearKiller

Couldn't one just use starter-relays from a Ford??

The junk-yards are full of them and they should be big enough to carry the load.

Also, is there a possibility of over-heating the bulbs, when burning both the high and low filaments at the same time, for continous periods??

Ace

They're not designed to be run like that. They'll overheat and burn out pretty quick.

wannadiesel

Yeah, a starter relay coil is not designed for that sort of use - not to mention that 3 starter relays would be about as much load on the switch as the headlights.

If you want junkyard relays, GM and Chrysler products from the early '90's and up are crawling with standard Bosch 30 amp relays like Ace and I used. On Chrysler stuff look on the driver's fender, most will have at least 3 relays there. The junkyards in my area are too proud of their parts, I can get new stuff for the same or less in most cases.

ChrisLib

That pretty good! On my old 86 that I did a relay deal on I had approx 11V with the lights on. Darn bulbs were yellow they were so dim (H-lamp switch was probably on it`s way out). After the realy conversion and a set of Silverstars it was about a 9000% improvement . I have been slowly scrounging (read...free) the parts to do the 93. Hopefully i`ll get it done before we dump the clocks back.

Rampage1967

That's the way my 91 was, could barely see by the dim yellow lights on a rainy night. I didn't even bother to test the voltages, just put relays in. Now the GE HO sealed beams are bright white & make road sighns glitter in broad daylight.