upgrading headlight wiring loom

[dansedgli]

Im in the process of changing my headlights. They were already semi sealed units but I have swapped them to new narva lenses and brighter globes. The ones that I got with the lenses are 100/55. I want to get brighter low beams as I mainly go out at night.

From doing a search I understand the globes might draw a bit too much current for the stock wiring.

Has anyone here made their own loom? What parts did you need and where did you buy them from? Did you use a seperate relay for both low and high beam?

I'd go to repco myself and have a look but the 4wd is in pieces and its pissing down with rain so Im not taking my motorbike.

Thanks guys,
Dan

[chimpboy]

Im in the process of changing my headlights. They were already semi sealed units but I have swapped them to new narva lenses and brighter globes. The ones that I got with the lenses are 100/55. I want to get brighter low beams as I mainly go out at night.

From doing a search I understand the globes might draw a bit too much current for the stock wiring.

Has anyone here made their own loom? What parts did you need and where did you buy them from? Did you use a seperate relay for both low and high beam?

I'd go to repco myself and have a look but the 4wd is in pieces and its pissing down with rain so Im not taking my motorbike.

Thanks guys,
Dan

I have.

I used a single unit that integrates 2 relays, plus a fuse for each. I also bought two H4 plugs from Autobarn and used some heavy cable that I happen to have rolls of. Also needed are three flat male spade fittings and some light-duty cable for the signal.

I used the driver's side stock headlamp plug as a signal source ie it drives the relays. So three wires (high beam +ve switched, low beam +ve switched, and ground) all run from that plug (using the spade lugs) to the fuse area next to the battery.

These are connected to the relay unit, which I mounted near the battery inside that space that has other, stock relays for air con etc in it.

From the battery runs some heavy cable to the relay unit.

Then from there runs some heavy cable to each headlamp, with one of the new H4 plugs soldered on. I just earthed them to the body near the lamps.

That's it.

I think I used 8mm^2 wire for the first headlight, and then ran on from there with 6mm^2 wire to the second one.

The integrated relay/fuse unit was $15 or so and is really good value, but I warn you that I had to open it up and adjust the relay arms and springs to make it work properly when carrying high current, as it had a tendency to stick in the "on" position due to the current flow. Now it's perfect though and I would definitely buy another one because it's more convenient to wire up.

The H4 plugs are about $4 each, cable is a few bucks a metre from Jaycar or wherever.

[D_Web]

As chimpboy said, it's a pretty straightforward job. I recently did mine, and took some happy snaps of the process which can be found here

[dansedgli]

Wow thanks for that guys.

Both of your write ups are great! Ill do this tomorrow before I start work. Ive got heaps of wiring gear lying around, I just need to buy the relays and the headlight plugs before I start.