a. I wouldn't be caught dead using a fuse in a headlight installation. Fuse blows - no lights until you solve the overload and replace the fuse. Circuit breaker trips on overload then resets. You still might have lights enough to limp somewhere.

b. No sense having 80A relays when you only have a 30A protected circuit. Thirty or forty amp relays will work fine behind a 30A breaker.

c. No way would I use a "plug and play" set-up unless there was no other alternative. Keep the wire runs as short as possible. All connections between harnesses spliced, soldered and shrink-wrapped.

d. As long as you're adding a relay-controlled headlamp circuit then you can also think about having the power cut when the ignition is "off" or the lights automatically switched on when the wipers are activated? Just a couple thoughts.

Sometimes it pays to have a wiring professional do the job vs. trying to cheap-out.

 

i agree with everything here except the use of a plug and play kit. if you get a good quality kit there should be no issue. i got one from LMC truck that is a nice kit.

 

Check out Rocketman’s relay kits.

https://www.rccinnovations.com/index.php?show=menu-hrk-all

 

I bought relay kit referenced in the thread below from Amazon. Soon to be installed.

https://forums.vintage-mustang.com/...ng-forum/1147486-66-coupe-what-going-my-headlights-dashlights.html#post10054962

 

I generally don't buy generic parts from the catalog places. They aren't that complicated or actually vehicle specific so I got a set off of "the dang internet giant" either of them for about $25, without looking I bet that's close to half of what a classic place sells nearly the same thing for.
Just be sure to get ones that have ceramic sockets where they go on the light.

 

Daniel Stern sells the finest quality relay kits and also has them completely assembled. Are they as cheap as the ones you've already found ?

No, they might be twice as expensive, I don't know. But you won't be buying the cheapest Chinese relays either. His kits do have a provision for a fuse or you can ask for a circuit breaker in place of the fuse. On Amazon I found a blade fuse type circuit breaker that automatically resets.

Daniel Stern Lighting Consultancy and Supply

I've bought several of Sterns kits and also his completed relay assemblies, which were perfectly sized for the vintage Mustang. A perfect companion for his Cibie lens / H-4 headlight upgrade.

Z

PS. no shopping cart on his website either. He actually wants to TALK to you before you buy anything . WOW ! What a novel idea, person to person customer service. Who knows, it might catch on ......

 

Daniel Stern sells the finest quality relay kits and also has them completely assembled. Are they as cheap as the ones you've already found ?

No, they might be twice as expensive, I don't know. But you won't be buying the cheapest Chinese relays either. His kits do have a provision for a fuse or you can ask for a circuit breaker in place of the fuse. On Amazon I found a blade fuse type circuit breaker that automatically resets.

Daniel Stern Lighting Consultancy and Supply

I've bought several of Sterns kits and also his completed relay assemblies, which were perfectly sized for the vintage Mustang. A perfect companion for his Cibie lens / H-4 headlight upgrade.

Z

PS. no shopping cart on his website either. He actually wants to TALK to you before you buy anything . WOW ! What a novel idea, person to person customer service. Who knows, it might catch on ......

Am about to order a kit from him. Parts kit for the relay, the lamps and the best (his recommendation) h4 bulbs. I have been reading his site for many years. I emailed him and got a near instant response with detailed explanations of the options. It basically comes down to I can't see as well at night as I used to so the best solution for headlamps is what I am looking for.


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I have used premade relay kits and they worked ok but I found the quality and gauge of the wire lacking.

Next go around I will make my own.

I only want one to take the amperage off the headlight switch, I dont drive my classic much at night.

 

The Amazon sourced relay kit that I linked to in the other thread has been working great since installing it. Relays are a generic Chinese unit, but work just fine. Wire quality was very good- solid crimps, ceramic insulators etc. They are a standard off the shelf relay, exact type escapes me at the moment, but high quality relays made by Omron or Bosch from Allied or Digikey will drop right in - which incidentally, are most likely also made in China. Welcome to global parts sourcing.

 

I've also worked with Daniel Stern on several occasions, and the experience is just as Zray related above. Highly recommended, a stand-up guy. Having someone who actually communicates with you personally to meet your exact needs is, well, almost unheard of in todays click and order world. No shopping cart, just people skills. Myself, I'd rather pay a bit more for high quality and service.

 

Headlight relay harness

I installed the CJPP kit along with H4 bulbs about four months ago, tremendous improvement over the stock setup and bulbs, I do drive at night. I mounted the relays behind my battery so they are out of sight unless you are really looking for them. I would do it again in a heartbeat.

 

I installed the CJPP kit along with H4 bulbs about four months ago, tremendous improvement over the stock setup and bulbs, I do drive at night. I mounted the relays behind my battery so they are out of sight unless you are really looking for them. I would do it again in a heartbeat.

I used the same kit. About a year old. No problems works great. Quality looked good to me.

 

Thanks all.
I totally missed the fuse vs. circuit breaker issue. I sort of figured that if NPD was selling the item that it was first rate. However, Dan Stern says: “Don't use self-resetting/auto-reset circuit breakers.” As with all things, there is disagreement regarding the numerous options!
I was considering a relay block which I could wire for the headlights, fog lights and horn. I’m not afraid of wiring.
I will check-out Stern and Rocketman.
I will report back.

 

I have used a kit from Painless wiring. It was an expensive kit...around 200-250. I picked it up new in box for 30 bucks at the New Braunfels swap meet. It was plug and play, top quality and easily installed. HUGE difference in lighting. I would do it again if I could find it for 30 bucks! Maybe not for 200 though.

 

I got my harness from Bronco Graveyard, about $30 I think. I've had no issues with it since I got it several years ago. I've since upgraded to LED headlights and it's still working fine.