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1967 - 1972 F-100 & Larger F-Series Trucks Discuss the Bumpsides Ford Truck

Headlight relay mod

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Old May 8, 2019 | 11:39 AM
  #1  
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Headlight relay mod

Just something I wanted to share. I did a bit of a new spin on the old relays inside the voltage regulator housing trick after installing a 3G alternator.
Something that always bothered me about hiding relays in the old regulator was not having the relays easily removed, so I modified the housing by mounting Delphi or weatherpak style relay sockets along with the fuses.


 
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Old May 8, 2019 | 12:23 PM
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Clever, Attempting about the same thing with and Ignition Module in a Motorcraft Housing.
 
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Old May 8, 2019 | 08:49 PM
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Originally Posted by GreyScar
Clever, Attempting about the same thing with and Ignition Module in a Motorcraft Housing.
Like a Duraspark? I have a couple old school finned aluminum lids for a voltage regulator that probably be a better heatsink if properly potted.
 
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Old May 9, 2019 | 01:12 AM
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I have some older Finned Motorcraft Housings that I heated up and dropped the Guts out of.
 
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Old May 9, 2019 | 10:50 AM
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I populated the original regulator connector with the P-side headlight wires and hard wired the relay socket blades to the regulator housing terminals.

I wired the main input and output power thru the backside using SAE connectors so not only are the relays and fuses removable but the entire unit is plug and play.


 
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Old May 9, 2019 | 12:23 PM
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You are a Craftsman my Friend.
 
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Old May 9, 2019 | 10:42 PM
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Thank you sir, and thanks for showing interest.

I put a lot of effort into this and was real happy with the result, I figured it would generate more responses here but I guess its generally considered as cool as old nail clippings for most

I tell you what, with the E code lamps this is now a pleasure to drive at night

 
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Old May 10, 2019 | 05:12 PM
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you need to sell those !!
Excellent work !!
 
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Old May 10, 2019 | 05:35 PM
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I am running Hella E code headlights in my 1971 F250 with a upgraded wiring harness that feeds full 12 volts to the lights. What a difference, like you said a real joy to drive at night.
 
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Old May 10, 2019 | 09:05 PM
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Not looking forward to having to replace my old Carello lamps, but the reflective surface is really deteriorating quickly. Probably going to try the Hellas unless I can find some Cibié/Valéo rectangulars for the '79.
Fantastic looking job Jon. Don't think I've seen any other discussions about hiding the wiring in the regulator, but it's a great idea. I like stealth, but rarely practice it!

I've got headlight relays and a horn relay (my model did not come with one) just standing right there in plain sight. Since I'm going to be running an internally regulated alt at some point, I might go to the trouble as well.
Not sure if my 105a large case 1G will ever die, but just in case, great idea.

What are you doing with your ignition module Gray Star? GM HEI style in the Dura Spark housing? Or did you mean an ignition module inside a voltage regulator body?
Oh, and what are you using for harness tape Jon?

Thanks guys.

Paul
 
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Old May 10, 2019 | 11:18 PM
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Originally Posted by MIKES 68 F100
you need to sell those !!
Excellent work !!
thought about it, wanted to make printed circuit boards even. In the end I'd need to stamp my own pieces and I haven't figured out a way to make it cost less to make than what they'd sell for (yet )

Originally Posted by old28
I am running Hella E code headlights in my 1971 F250 with a upgraded wiring harness that feeds full 12 volts to the lights. What a difference, like you said a real joy to drive at night.
followed your whole thread

Originally Posted by 1TonBasecamp
Not looking forward to having to replace my old Carello lamps, but the reflective surface is really deteriorating quickly. Probably going to try the Hellas unless I can find some Cibié/Valéo rectangulars for the '79.
Fantastic looking job Jon. Don't think I've seen any other discussions about hiding the wiring in the regulator, but it's a great idea. I like stealth, but rarely practice it!

I've got headlight relays and a horn relay (my model did not come with one) just standing right there in plain sight. Since I'm going to be running an internally regulated alt at some point, I might go to the trouble as well.
Not sure if my 105a large case 1G will ever die, but just in case, great idea.

What are you doing with your ignition module Gray Star? GM HEI style in the Dura Spark housing? Or did you mean an ignition module inside a voltage regulator body?
Oh, and what are you using for harness tape Jon?

Thanks guys.

Paul
I picked up the idea from the Ford Falcon news forums some years back, but with spade connections pushed on the relay tangs.

I'm using high heat Tesa tape, like a woven vinyl tape intended for harness wrap- http://Tesa's Most Advanced High Hea..._eOK1Cb0X14PH5

Can't get the link to work, look for Tesa tape 51036
 
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Old May 11, 2019 | 01:51 AM
  #12  
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GaryKip
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Smooth looking electrical work, very clean. Thanks for sharing the info on the "stealth relay box" .
 
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Old May 11, 2019 | 01:57 AM
  #13  
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Originally Posted by 1TonBasecamp
Not looking forward to having to replace my old Carello lamps, but the reflective surface is really deteriorating quickly. Probably going to try the Hellas unless I can find some Cibié/Valéo rectangulars for the '79.
Fantastic looking job Jon. Don't think I've seen any other discussions about hiding the wiring in the regulator, but it's a great idea. I like stealth, but rarely practice it!

I've got headlight relays and a horn relay (my model did not come with one) just standing right there in plain sight. Since I'm going to be running an internally regulated alt at some point, I might go to the trouble as well.
Not sure if my 105a large case 1G will ever die, but just in case, great idea.

What are you doing with your ignition module Gray Star? GM HEI style in the Dura Spark housing? Or did you mean an ignition module inside a voltage regulator body?
Oh, and what are you using for harness tape Jon?

Thanks guys.

Paul
Putting HEI Module in a Ford Ignition Box, Lot easier to get your Hands Own. Been Collecting a Few of the Older Finned Boxes off Epay.......
 
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