Author Topic: Headlight Relays  (Read 15118 times)

Offline VTMopar

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Headlight Relays
« on: March 16, 2010 - 12:19:47 AM »
Chryco:   I know this would probably be a repeat... but I've searched the site and can't really find a handy reference on "how to" install relays in my Challenger's headlight system to avoid battery drain and improve overall safety.   Any chance you could "take this from the top" for those of us who are electrically challenged?    Also -- do we need to replace the existing wiring harness/switches -- and how can we keep it looking as original as possible?   Any help is -- as always -- much appreciated. 

VT Mopar
VT MOPAR




Offline Chryco Psycho

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Re: Headlight Relays
« Reply #1 on: March 16, 2010 - 01:28:31 AM »
Sure
  The headlight switch can remain as is . This will drop the load on the switch down to Milli-amps
  A typical relay has 5 connections 85,86 switching circuit   & 87,30 load circuit & 87a which is not used ,  these pairs of terminals are across from each other on the relay .
I usually hide the relays behind the left headlights in front of the rad wall .
  The stock headlights use a red & purple wire for low & high beams so the red & purple wire from the firewall / headlight switch go to the 85 terminal on both relays , one to each relay , the red & purple wire attach to the 87 terminal going out to the headlights .Neither of the wires need to be extended as the wire will reach both sides of the relay as is .
   The 86 terminal is grounded , I ground to the bolt by the battery tray where the headlights are grounded , this wire is also basically hidden .
   I run a 14 ga wire from the battery terminal on the start relay out to the #30 connection on both relays , & I install a fusable link into that wire for safety,this wire will need to be taped into the harness to hide it .
 Now the current for the headlights runs from the start relay on the inner fender through the headlight relay directly to the lights , the power through the firewall & headlight switch inside the car is extremely small & only activates the headlight relay
   
« Last Edit: March 16, 2010 - 03:19:27 AM by Chryco Psycho »

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Offline MEK-Dangerfield

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Re: Headlight Relays
« Reply #2 on: March 16, 2010 - 05:03:00 AM »
 

Mike

1970 Challenger - SOLD
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Offline willard

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Re: Headlight Relays
« Reply #3 on: March 16, 2010 - 05:45:41 AM »
That was my first mod and it really helps. in my case 20 amp relay was blown when I turned the high beams on ;) I switched to 30  amp relay for hig beam then - it is 4 bulbs and they draw much current.
1970 383 R/T SE

Offline Katfish

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Re: Headlight Relays
« Reply #4 on: March 16, 2010 - 07:11:39 AM »
This was a great upgrade for me as well.  No more dim lights at idle.  I put mine under the battery tray.

Offline brads70

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Re: Headlight Relays
« Reply #5 on: March 16, 2010 - 11:11:28 AM »
 :popcorn: great info thanks all! electrical is my weak point, intimidating somehow.
Brad
1970 Challenger 451stroker/4L60 auto OD
Barrie,Ontario,Canada
Proud to own one of the best cars ever made!!!!!

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Offline MEK-Dangerfield

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Re: Headlight Relays
« Reply #6 on: March 16, 2010 - 11:18:13 AM »
:popcorn: great info thanks all! electrical is my weak point, intimidating somehow.

Brad,

   It's pretty easy. Things either work, or they go up in smoke.   :scared:

Mike

1970 Challenger - SOLD
2016 SXT+.  1 of 524 SXT+'s in Plumb-crazy for 2016.

Offline Chryco Psycho

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Re: Headlight Relays
« Reply #7 on: March 16, 2010 - 11:23:34 AM »
MEK diagram is correct except the 85 & 86 wires are reversed which makes no difference to the way the system works & the colors for the factory wires are incorrect

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Offline dodj

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Re: Headlight Relays
« Reply #8 on: March 16, 2010 - 03:41:18 PM »
Katfish, what's the third relay for?
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Offline UKcuda

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Re: Headlight Relays
« Reply #9 on: March 16, 2010 - 05:21:04 PM »
Here are mine - hooked off the strater solenoid - the blue and red to the right is blade fuses for the circuits.

They don't look great but I wanted them somewhere I can get at them easy on a lonely road in the dark!
'72 'cuda

Offline brads70

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Re: Headlight Relays
« Reply #10 on: March 16, 2010 - 05:24:35 PM »
Brad,

   It's pretty easy. Things either work, or they go up in smoke.   :scared:

 :scared: ya that's the problem! :bigsmile:
Brad
1970 Challenger 451stroker/4L60 auto OD
Barrie,Ontario,Canada
Proud to own one of the best cars ever made!!!!!

My restoration thread 
http://www.cuda-challenger.com/cc/index.php?topic=59072.0
 My handling upgrade post
http://www.cuda-challenger.com/cc/index.php?topic=73985.0

Offline RB2929

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Re: Headlight Relays
« Reply #11 on: March 16, 2010 - 05:31:59 PM »
The headlamp relays, is this a mod that Slotts (JS Restoration) or someone else could build?

They could build the headlamp relays.  Make them look nice/professional.  Make sure customer installation is very easy.  Sell them at a fair profit.  Everybody wins. :woohoo:

Just a thought,
Ron
« Last Edit: March 16, 2010 - 06:55:07 PM by RB2929 »

Offline brads70

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Re: Headlight Relays
« Reply #12 on: March 16, 2010 - 05:33:50 PM »
The headlamp relays, is this a mod that Slotts (JS Restoration) or someone else could build?

They could build the headlamp relays.  Make them look nice/professional.  Make sure customer installation is very easy.  Sell them at a far profit.  Everybody wins. :woohoo:

Just a thought,
Ron



I'd support that! :2thumbs:
Brad
1970 Challenger 451stroker/4L60 auto OD
Barrie,Ontario,Canada
Proud to own one of the best cars ever made!!!!!

My restoration thread 
http://www.cuda-challenger.com/cc/index.php?topic=59072.0
 My handling upgrade post
http://www.cuda-challenger.com/cc/index.php?topic=73985.0

Offline Katfish

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Re: Headlight Relays
« Reply #13 on: March 16, 2010 - 05:43:57 PM »
I added the 3rd relay for the running/parking lights.

Offline UKcuda

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Re: Headlight Relays
« Reply #14 on: March 16, 2010 - 05:51:57 PM »
Quote
is this a mod that Slotts (JS Restoration) or someone else could build?

Funny you should say that, I have a friend here in the UK who does classic American car resto. work and we were wondering about putting a neat headlamp relay kit together.

If anyone is interested we are currently testing a solid state 5 volt instrument panel regulator which doesn't need any heat sink and has an adjustable output voltage.  Price would be about $35, but obviously there would be shipping costs to the states so it may not be worthwhile for you guys.
'72 'cuda