My DIY headlight harness
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Fleet Mechanic
Joined: May 2013
Posts: 1,256
Likes: 4
From: NC
My DIY headlight harness
After running across the Brighter Brights, Whiter Whites thread on here for the headlight relay conversion, I decided to do some more reading and started on a headlight harness for my 89 IDI. heres a link to the one I'm basing mine off of Headlight Relay Conversion!!! - Ford Truck Fanatics
Heres what I'm doing
draws power off drivers side battery through ring terminal.
12 AWG wire In factory green, red, black colors
Relays and sockets off amazon
triggers relays through 18 gauge wire from old headlight bulb
using ford headlight pigtails with the 12 gauge wire soldered to them ( id recommend 14 gauge, kind of a snug fit in the plugs.)
fusing both high and low beam circuits separately with weatherproof ATC fuse holders.
Crimping/ and or soldering connections
wrapping every connection possible with heatshrink
dielectric grease on exposed connections/ relay sockets.
and My Favorite, tons of 3/8 in Wire loom
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[IMG]
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Heres what I'm doing
draws power off drivers side battery through ring terminal.
12 AWG wire In factory green, red, black colors
Relays and sockets off amazon
triggers relays through 18 gauge wire from old headlight bulb
using ford headlight pigtails with the 12 gauge wire soldered to them ( id recommend 14 gauge, kind of a snug fit in the plugs.)
fusing both high and low beam circuits separately with weatherproof ATC fuse holders.
Crimping/ and or soldering connections
wrapping every connection possible with heatshrink
dielectric grease on exposed connections/ relay sockets.
and My Favorite, tons of 3/8 in Wire loom
[IMG]
[/IMG][IMG]
[/IMG]
Postmaster
Joined: Nov 2011
Posts: 3,533
Likes: 17
From: SW Florida
Good deal, I'm fixin' to make my own harness here in a bit too. Just have to move my single relay I added to a mounting rail I plan on making so I can have multiple relays in one spot. Two for headlights, one for air compressor, and probably another one or two for off-road lighting when I find a decent set of 100W lights.
+1 for soldering/heatshrinking... way to do it right. I plan on using sealed relays and connectors also.
+1 for soldering/heatshrinking... way to do it right. I plan on using sealed relays and connectors also.
Thread Starter
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Fleet Mechanic
Joined: May 2013
Posts: 1,256
Likes: 4
From: NC
sockets
relays
the sockets are good. I haven't finished it yet, so idk on the relays, you can get bosch/tyco ones (not sure who manufactures them now) for around 16 bucks for two shipped from rock auto.
I plan on mounting the relays on the factory bracket on the drivers side, I was gonna mount them on the passenger side near the radiator support, but changed my mind since they would be hard to get to and I now have to extend a few wires.
relays
the sockets are good. I haven't finished it yet, so idk on the relays, you can get bosch/tyco ones (not sure who manufactures them now) for around 16 bucks for two shipped from rock auto.
I plan on mounting the relays on the factory bracket on the drivers side, I was gonna mount them on the passenger side near the radiator support, but changed my mind since they would be hard to get to and I now have to extend a few wires.
Senior User
Joined: May 2005
Posts: 326
Likes: 1
From: Carthage, MO
I mounted my relays between the starter solenoid and the jack on the passenger fender. +12v is close and convenient on the hot side of the solenoid (We gas guys don't have the driver side batteries.)
I get my female sockets at NAPA, that's a common item. The male sockets, though, are harder to find. Ebay is where I get those:
9004 9007 HB5 Male Connector HID Plug Socket Adaptor | eBay
I get my female sockets at NAPA, that's a common item. The male sockets, though, are harder to find. Ebay is where I get those:
9004 9007 HB5 Male Connector HID Plug Socket Adaptor | eBay
Thread Starter
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Fleet Mechanic
Joined: May 2013
Posts: 1,256
Likes: 4
From: NC
I mounted my relays between the starter solenoid and the jack on the passenger fender. +12v is close and convenient on the hot side of the solenoid (We gas guys don't have the driver side batteries.)
I get my female sockets at NAPA, that's a common item. The male sockets, though, are harder to find. Ebay is where I get those:
9004 9007 HB5 Male Connector HID Plug Socket Adaptor | eBay
I get my female sockets at NAPA, that's a common item. The male sockets, though, are harder to find. Ebay is where I get those:
9004 9007 HB5 Male Connector HID Plug Socket Adaptor | eBay
And I was going to do like that, then I realized I'd be putting more amperage draw through the old cables, v.s. right off the battery terminal bolt. already had it measured and ready to go on, then changed my mind.
Thread Starter
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Fleet Mechanic
Joined: May 2013
Posts: 1,256
Likes: 4
From: NC
I'm just about finished with the harness, just need to pick up some more wire loom and make a few connections.
just thought I'd let y'all now about the way I crimp connections, I don't use a cheap stamped wire stripper/crimper combination tool, but a set of heavy cast pliers, like these.
The advantage to these, is they allow one to make much stronger crimp connections. heres a pic.
just thought I'd let y'all now about the way I crimp connections, I don't use a cheap stamped wire stripper/crimper combination tool, but a set of heavy cast pliers, like these.
The advantage to these, is they allow one to make much stronger crimp connections. heres a pic.
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Thread Starter
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Fleet Mechanic
Joined: May 2013
Posts: 1,256
Likes: 4
From: NC
got some loom, heres the harness, have to shorten the wires going from the fuseholder to the battery, and put it in. Tested it last night and it works, can't tell much difference though with the engine off. got to looking, theres a harness on my IDI that is routed on the driverside underneath the battery tray and coolant overflow, seems like a good place to run the harness, out of sight, out of the way.
Thread Starter
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Fleet Mechanic
Joined: May 2013
Posts: 1,256
Likes: 4
From: NC
results of harness
hate to bring back an old thread, but the harness is in, and has greatly improved the visibility when driving at night. low beams are brighter and wider, not bright enough to cause people to flash you however, high beams really improved more so then the low beams, much longer brighter beam. The color has gone from a yellowish color to a brilliant white, not in the 6k HID spectrum, but probably more along the lines of 3800- 4k. In all honesty, I am completely satisfied with the headlight out put on the truck.
More Turbo
Joined: Dec 2007
Posts: 641
Likes: 3
From: Umicorn UtopiaFantasyLand
hate to bring back an old thread, but the harness is in, and has greatly improved the visibility when driving at night. low beams are brighter and wider, not bright enough to cause people to flash you however, high beams really improved more so then the low beams, much longer brighter beam. The color has gone from a yellowish color to a brilliant white, not in the 6k HID spectrum, but probably more along the lines of 3800- 4k. In all honesty, I am completely satisfied with the headlight out put on the truck.
Wow, good job! Was wondering, in earlier post, you were talking about the high-temp sockets with a ceramic piece. Where can you get that? I need to upgrade all of my bulb sockets on my 96, on the whole truck.
Thread Starter
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Fleet Mechanic
Joined: May 2013
Posts: 1,256
Likes: 4
From: NC
BEST QUALITY 9004 / 9007 / HB1 / HB5 High Temperature Headlight Socket / Plug / Connector. We Welcome Custom Orders! All of our Head Light Sockets / Plugs / Connectors are made with USA Wire! - Innova Design & Dist. Inc. (909) 971-0000
No need to upgrade any other bulb plugs, unless they are damaged, in which case replace them. turn signals, taillights, marker lights do not put off enough heat to warrant it.
More Turbo
Joined: Dec 2007
Posts: 641
Likes: 3
From: Umicorn UtopiaFantasyLand
If your going with higher watt headlight bulbs, they make high temp ceramic plugs, you can get them off ebay, or through here.
BEST QUALITY 9004 / 9007 / HB1 / HB5 High Temperature Headlight Socket / Plug / Connector. We Welcome Custom Orders! All of our Head Light Sockets / Plugs / Connectors are made with USA Wire! - Innova Design & Dist. Inc. (909) 971-0000
No need to upgrade any other bulb plugs, unless they are damaged, in which case replace them. turn signals, taillights, marker lights do not put off enough heat to warrant it.
BEST QUALITY 9004 / 9007 / HB1 / HB5 High Temperature Headlight Socket / Plug / Connector. We Welcome Custom Orders! All of our Head Light Sockets / Plugs / Connectors are made with USA Wire! - Innova Design & Dist. Inc. (909) 971-0000
No need to upgrade any other bulb plugs, unless they are damaged, in which case replace them. turn signals, taillights, marker lights do not put off enough heat to warrant it.
Thanks for the info!
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