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Thread: Made a headlight wire harness.

  1. #1
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    Default Made a headlight wire harness.

    I've been messing with my lights lately. I just added a new set (driving). After that I got a wild hair and tested the volts at the headlight. I came up with 11.4 volts motor off. So I made a new harness for it. Yesterday I went to auto store and bought a few things to start.

    15 feet on 10 gauge wire= $5.55
    2 x 30 amp relay= $9.98
    Fuse block= $9.99
    10 gauge connectors= $4.00

    total= $29.52
    minus military discount 10%= $2.95

    For a grand total of= $26.57

    You could do it cheaper but I wanted the nice fuse box. You only need to fuses. You could also use the cheaper 12 gauge wire.


    Here is a pic of the fuse box it holds 6 fuses.




    And the relays. I still need to get two sheet metal screws to finish it off.




    Here is a diagram if anyone wants to try it.


    I rechecked the system after and got 12.55 volts on drivers side and 12.54 volts on pass side with the motor off. If you want to test your system take a large gauge wire and hook it to the positive post on the battery. With the lights on touch the wire to the headlight (metal post on the back of the headlight). The very top post is the low beam. Watch the light get brighter.

  2. #2
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    Default

    Here is a comparison of the new light setup VS old light setup.

    Headlights



    Headlights and fogs



    Headlights, fogs, and driving lights


  3. #3
    Zombie Hunting Infidel silverbullet's Avatar
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    you got some bright lights there boss

  4. #4
    Hiding in plain sight jeepfever's Avatar
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    Nice job with the comparison shots. It really shows the difference and improvement that your efforts made.

  5. #5
    Senior Member HillBillE's Avatar
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    Nice job! I did the same thing on my CJ a while back (although it's not as purty ) and man what a difference in light output!

    I had sourced a set of 7" round Cibie' lights, and they are supposed to be great. But with the factory harness on a 30 year old rig, it just wasn't so.

    The factory uses the smallest wire they can get by with, (lighter wire = cheaper to build) add in a few years of corrosion, wear and tear, and the old lights just don't have it anymore.

    Glad to see you upgraded the grounds also, a lot guys just upgrade the 'hot' wire. It needs both to work the best.


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