Headlight harness for higher wattage H4 bulbs

[thrasher]

This is for a dual headlight system using only one bulb per side for cars like 78-81 Malibu/El Camino

Night driving in the winter really sucks. I almost hit a dog the other night and it made me really want to update my headlight harness and start a small project.
Keep in mind I'm not an electronics expert but after doing a lot of research I've figured out a lot of different things buy reading about other peoples problems and how they've solved them.

Currently I have Cibie E Code lenses with NARVA 60/55w bulbs.
While the light is already way better than stock I want to install my 100/90w bulbs but doing so is a no go on these cars because of the stock wiring.
What I'll be doing is taking a known manufacturers product that a lot of people use as is and making it better and more reliable.

I made someone on ebay a low offer of 15 bucks shipped on a Putco 230004HW system and they accepted.
This harness has been reported to have 12 awg power and ground wires which is just fine for 100 watt bulbs.
If you wanted to run 130+ watt bulbs you'd pass on this harness and build your own from scratch with 10 awg wire.
This is not my video but this is the harness I'll be modding.
http://www.youtube.com/watch?v=AHql9CZHN1g


So the first mods to the harness are, $8 for two good waterproof fuses http://tinyurl.com/nxkuyhp , and $6 for two ceramic headlight connectors to withstand higher temperatures. http://tinyurl.com/mkje7r7
$15 for the harness and $14 for the first mods is $29 so far.

One of the big problems with the cheaper harnesses is the unreliable relays. I might see if I can find some good used relays off a Honda to replace the ones on the harness. Those are usually around $25+ each when new.
If I can find good waterproof Hella or Tyco/Bosch relays for cheap enough I might go that way.
You can start to see why a good harness from Susquehanna Motorsports or Caspers Electronics costs over $90. You don't get their labor for free either.

I'll probably be posting some pictures and details when stuff arrives.

 

[pontiacgp]

Re: Headlight harness for H4 higher wattage bulbs

You could have easily wired in a couple of relays for cheaper than that. I don't know why he used yellow covering cause yellow is the color of the wiring for the air bag system in all cars. I have 4 hella lenses and 4 hid's for my headlights and that is the best lighting I have found

 

[thrasher]

What kind of relays would you use? Good reliable ones aren't cheap.

Many years ago I had the 100/90w H4's hooked up on a Honda with heat resistant sockets, 10 awg wire, and Hella relays.
Heat resistant, what a joke that was. The "heat resistant" plastic connectors started melting and I had to remove them.
I ended up just using the standard metal connectors with a couple layers of shrink tubing around them for protection.

After I removed them and sold the car I learned about ceramic headlight connectors

 

[pontiacgp]

I use the cheap relay I get from my friend who owns a shop. As long as you mount them with the connectors facing down so it doesn't fill up with water I have never had any issues with them. I've had the same relay on my electric cooling fan for 4 summers

 

[XCESSIV6]

JEGS AND SUMMIT SELL A H4 HARNESS FOR BOTH LIGHT BEEN RUNNING FOR YEARS WITH 100W/90 ON ALL 4

 

[thrasher]

As mentioned the relays that come with this harness are crap so I started searching for a quality interchange.
After searching through complaints and part numbers on the web I narrowed the good relays down to a Honda/Acura part# 39797-SE0-004
That relay is made in Japan by Mitsuba. Part# RC-2201
They're rated at 20Amp but some Honda boys say they can handle 30Amps.

Probably get those relays at the wrecking yard for $5 bucks.
The other option is to get some new waterproof ones that are rated for up to 40Amps, but that would be closer to $30-$40 for the pair.

Harness $15, Waterproof Fuses $8, Ceramic Headlight Connectors $6, Mitsuba RC-2201 Relays $5 = $34.00 so far.

 

[H2O gbodies]

I stock HD commercial grade 40A Tyco relays as one of the relays I use in my harness kits. I can offer them at $8 ea. plus shipping. They are rated @ 500,000 switching cycles for 30A and 250,000 cycles @ 40A.

 

[thrasher]

I stock HD commercial grade 40A Tyco relays as one of the relays I use in my harness kits. I can offer them at $8 ea. plus shipping. They are rated @ 500,000 switching cycles for 30A and 250,000 cycles @ 40A.

That certaintly sounds like it has a better life cycle than the relays I found.
Is it a five terminal SPST with two 87 pins?
That's what I've really been trying to find to avoid splicing wires.

Since Tyco is now making Bosch I would think the ratings would be the same.
The other relays I've been looking at are:
Bosch 0 332 019 150 _______ 200,000 Cycles @ 40A
Tyco V23234 C1001 X005
http://www.waytekwire.com/item/75401/
http://www.bpg-inc.com/std_mini.htm
http://theelectricaldepot.com/index.php ... cts_id=435

Compared to those two the Hella HL87118 ratings don't look good at all. 100,000 Cycles @ 30A

 

[thrasher]

Found the sleaving I want to use. It's from a company called Techflex.
I think I want to use their FlexoHD or the Nylon Multifilament.

 

[H2O gbodies]

There are two types: dual 87 terminals are just dual outputs once 86 is triggered. 87A is tied to 30 until the field collapses by triggering 86-then 87A is dead. You still need 2 relays for each low and high beam. I terminate mine using the dedicated relay bases also.