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Old 09-08-2007, 01:31 PM   #1
VinceY
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Good reason to install headlight relays

I have been wanting to install relays on my headlights and finally found the reason for it. The other day I touched the stem on my switch and actually burnt my finger. Normal headlights, by the way.
Anyway, the switch felt like it was toasted, so I replaced it this morning and wired in relays. Check out the switch and how fried it was compared to the new one. White bakelight on the new switch instead of chared like the old. Hole melted in the stem. It melted my harness a bit also, picture 2.
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Old 09-08-2007, 08:36 PM   #2
sandking
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Re: Good reason to install headlight relays

Not good. This must have been caused by a loose or dirty connection. The stock headlights draw just over 9 amps, I am sure the switch is rated for it. Dont get me wrong, I swear by relays also, but if your connections are not good, it will happen again.
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Old 09-09-2007, 08:15 AM   #3
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Re: Good reason to install headlight relays

Relays allow for the lights to get the full 12 volts available, good idea Vince and none to soon either.

The bigger issue with out set up is the power has to travel the entire harness before it gets back to the headlights, lending alot of different ways to cause melt downs.
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Old 09-09-2007, 09:27 AM   #4
Big J
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Re: Good reason to install headlight relays

Post up some pics of your relay install with some info on what relays you used and how you installed them... Please...... I'm sure its a simple thing to do but pics always help....lol...
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Old 09-09-2007, 11:32 AM   #5
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Re: Good reason to install headlight relays

The front part of the switch is the dimmer for the dash lights. Head light switches have built in circuit breakers, so if it was drawing too much the headlights would turn off and on as the circuit breaker heated and cooled.
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Old 09-09-2007, 11:34 AM   #6
bouncytruck
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Re: Good reason to install headlight relays

Quote:
Post up some pics of your relay install with some info on what relays you used and how you installed them... Please...... I'm sure its a simple thing to do but pics always help....lol...
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Last edited by bouncytruck; 09-09-2007 at 11:35 AM.
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Old 09-11-2007, 09:53 AM   #7
VinceY
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Re: Good reason to install headlight relays

Quote:
Originally Posted by Big J View Post
Post up some pics of your relay install with some info on what relays you used and how you installed them... Please...... I'm sure its a simple thing to do but pics always help....lol...
Here is a couple of pics of my install. Keep in mind that the PO left me with a wiring nightmare so it is not pretty. I put in a terminal block to take the power leads for all the stereo components that the PO was powering off the battery post. One day I will clean it all up.
I added a trouble light out of a 93 chev truck that reels out to the back of the truck and then added the relays. The hood does clear everything but it is close where I choose to install. I wired everything in exactly as per the thread below. There is another thread that uses the same wiring diagram in FAQ also. All the parts are easily availble at your favorite parts store. Yellow wires are the fused power feeds. I used #10 AWG wire which is good for 30 Amps. 30 Amp Relays. I also installed new 3 prong connectors for each headlight. Installed the H4 halogen headlights so that I can put in some extra wattage bulbs (don't tell anyone). Standard is 55 low 60 high. I just happened to find some 100 high 80 low bulbs (these are from an off road dealer).
It took me a Saturday morning.
http://67-72chevytrucks.com/vboard/s...d.php?t=235214
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1947 Studebaker M5 project to match the camping trailer.
1950 Chev 4x4 Pickup
1958 Shasta Airflyte Travel trailer (fresh restoration)
1971 C/10 Pickup(Frame off Restoration)
1972 K5 Blazer CST (Daily Driver & My Company Truck)
1976 Honda CB750 Bobber
1988 Jaguar XJ12
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Old 09-11-2007, 04:56 PM   #8
jaros44sr
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Re: Good reason to install headlight relays

Nice work, any chance of water, or will grease solve it. Better looking than your ould headlite switch. Any leads on the H4 bulbs? J.
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