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The biggest problem here is the undersized wiring in the head light circuit and a poorly designed headlight switch.
There is a tech article called Whiter Whites, Brighter Brights where the headlights are re-wired in the engine compartment to relieve the headlight switch of some amperage by wiring relays to the headlight switch and then the actual headlights to the other side (battery side) of the relays.
This does two things. Reduces the ampere load on the headlight switch to a level the switch can handle, and gives FULL BATTERY VOLTAGE to the headlights making them brighter. The relays will fit on the side wall aft of the battery and all the associated wiring will tuck in with the wire loom across the front.
Use 12Ga wire from the Relays to the lamps.
My lights are 20-25% brighter now, (10.5v vs 13.5v), and my headlight switch is cool to the touch when on for a while. My dash used to get hot around the switch. Not now.
Hey Larry, I just did the upgrade you referred to, what a difference in light output. Simple job and great results. I would highly recommend this upgrade to anyone. Check it out in my gallery.
im thinking about doing that, where did you get those nice connectors for the headlights?
and to they make them to plug into the factory headlight socket, im not a big fan of butchering a trucks wireing harness.
Larry, I assume that the "Whiter Whites" will work with later model trucks as you've already done it to your "94. Just curious, as the header in the tech article says for '60's and "70's Ford trucks. Did you have to do anything different from the article?
Regards, Rick
My truck is a 94 and I dident have to do anything different except for the fact that I used the 12 g wire in the whole upgrade, even the ground wire which should be the same size as your power wire.
The connectors are made by CalTerm, I picked them up at a local auto parts store. By using these connectors, I was able to tape back the drivers side factory connector, untouched. On the passenger side, with the relays mounted in the location I chose all I had to do was cut the red and green wire off the factory connector and put female spade style terminals onto the ends of the wires and then plug them right into the relays without any other changes. I then tied back the factory connector on the drivers side with the black wire still attached to the connector. If you ever wanted to return the truck to the origianal configuration, you would only have to solder the two wires back onto the passenger side connector and plug them back in, thats it!
so i have silverstar bulbs now, do you think they would be any brighter than they are currently? and i may do this anyways because ive been having problems with my dimmer switch. i think the problems fixed but i cant take chances.
I went to the local parts store and they sell replacement headlight sockets. That means you can just protect the stock socket from the elements and connect wires to the replacement and never worry about having to cut factory wires. They were only $5 apiece. I'm going to install them this week-end. I'll have pictures when I do