Good reason to install headlight relays - The 1947 - Present Chevrolet & GMC Truck Message Board Network

VinceY · 09-08-2007, 01:31 PM

I have been wanting to install relays on my headlights and finally found the reason for it. The other day I touched the stem on my switch and actually burnt my finger. Normal headlights, by the way.
Anyway, the switch felt like it was toasted, so I replaced it this morning and wired in relays. Check out the switch and how fried it was compared to the new one. White bakelight on the new switch instead of chared like the old. Hole melted in the stem. It melted my harness a bit also, picture 2.

sandking · 09-08-2007, 08:36 PM

Not good. This must have been caused by a loose or dirty connection. The stock headlights draw just over 9 amps, I am sure the switch is rated for it. Dont get me wrong, I swear by relays also, but if your connections are not good, it will happen again.

vtblazer · 09-09-2007, 08:15 AM

Relays allow for the lights to get the full 12 volts available, good idea Vince and none to soon either.

The bigger issue with out set up is the power has to travel the entire harness before it gets back to the headlights, lending alot of different ways to cause melt downs.

Big J · 09-09-2007, 09:27 AM

Post up some pics of your relay install with some info on what relays you used and how you installed them...

Please...... I'm sure its a simple thing to do but pics always help....lol...

pumpkin · 09-09-2007, 11:32 AM

The front part of the switch is the dimmer for the dash lights. Head light switches have built in circuit breakers, so if it was drawing too much the headlights would turn off and on as the circuit breaker heated and cooled.

bouncytruck · 09-09-2007, 11:34 AM

Quote:

Post up some pics of your relay install with some info on what relays you used and how you installed them... Please...... I'm sure its a simple thing to do but pics always help....lol...

VinceY · 09-11-2007, 09:53 AM

Quote:

Originally Posted by Big J

Post up some pics of your relay install with some info on what relays you used and how you installed them...

Please...... I'm sure its a simple thing to do but pics always help....lol...

Here is a couple of pics of my install. Keep in mind that the PO left me with a wiring nightmare so it is not pretty. I put in a terminal block to take the power leads for all the stereo components that the PO was powering off the battery post. One day I will clean it all up.
I added a trouble light out of a 93 chev truck that reels out to the back of the truck and then added the relays. The hood does clear everything but it is close where I choose to install. I wired everything in exactly as per the thread below. There is another thread that uses the same wiring diagram in FAQ also. All the parts are easily availble at your favorite parts store. Yellow wires are the fused power feeds. I used #10 AWG wire which is good for 30 Amps. 30 Amp Relays. I also installed new 3 prong connectors for each headlight. Installed the H4 halogen headlights so that I can put in some extra wattage bulbs (don't tell anyone). Standard is 55 low 60 high. I just happened to find some 100 high 80 low bulbs (these are from an off road dealer).
It took me a Saturday morning.
http://67-72chevytrucks.com/vboard/s...d.php?t=235214

jaros44sr · 09-11-2007, 04:56 PM

Nice work, any chance of water, or will grease solve it. Better looking than your ould headlite switch. Any leads on the H4 bulbs? J.

VinceY · 09-12-2007, 08:10 AM

Quote:

Originally Posted by jaros44sr

Nice work, any chance of water, or will grease solve it. Better looking than your ould headlite switch. Any leads on the H4 bulbs? J.

The pictures show lots of dust on my inner fender so I don't think water or grease is an issue. As far as the bulbs, I got them from a buddy and I think he gets them from a quad/snow machine dealer.

Big J · 09-12-2007, 02:32 PM

Looks good to me.... I've been wanting several of those trouble lights for all of my rides.... Nice work....

jaros44sr · 09-12-2007, 05:07 PM

Quote:

Originally Posted by VinceY

The pictures show lots of dust on my inner fender so I don't think water or grease is an issue. As far as the bulbs, I got them from a buddy and I think he gets them from a quad/snow machine dealer.

Thanks, so do your headlites work? Nice fix and thanks for all the information... J.

VinceY · 09-12-2007, 05:22 PM

Quote:

Originally Posted by jaros44sr

Thanks, so do your headlites work? Nice fix and thanks for all the information... J.

They do work better.

09-08-2007, 08:36 PM	#2
sandking .....I am working on it..... Join Date: Jul 2007 Location: Anaheim Hills, Ca Posts: 960	Re: Good reason to install headlight relays Not good. This must have been caused by a loose or dirty connection. The stock headlights draw just over 9 amps, I am sure the switch is rated for it. Dont get me wrong, I swear by relays also, but if your connections are not good, it will happen again. __________________ . . . . . View my build thread HERE

09-09-2007, 08:15 AM	#3
vtblazer Registered User Join Date: Oct 2003 Location: Central Vermont Posts: 8,538	Re: Good reason to install headlight relays Relays allow for the lights to get the full 12 volts available, good idea Vince and none to soon either. The bigger issue with out set up is the power has to travel the entire harness before it gets back to the headlights, lending alot of different ways to cause melt downs.

09-09-2007, 09:27 AM	#4
Big J Its lookin' like a Blazer! Join Date: Aug 2003 Location: Gods Country, KY Posts: 1,773	Re: Good reason to install headlight relays Post up some pics of your relay install with some info on what relays you used and how you installed them... Please...... I'm sure its a simple thing to do but pics always help....lol... __________________ BAZINGA! My Build

09-09-2007, 11:32 AM	#5
pumpkin Registered User Join Date: Apr 2006 Location: East Sooke B.C. Canada Posts: 543	Re: Good reason to install headlight relays The front part of the switch is the dimmer for the dash lights. Head light switches have built in circuit breakers, so if it was drawing too much the headlights would turn off and on as the circuit breaker heated and cooled.

09-11-2007, 04:56 PM	#8
jaros44sr Registered User Join Date: May 2006 Location: Philadelphia, Pa. 19454 Posts: 9,437	Re: Good reason to install headlight relays Nice work, any chance of water, or will grease solve it. Better looking than your ould headlite switch. Any leads on the H4 bulbs? J. __________________ Semper Fi...Uncle Sam, you da man All parts offered to help are free, unless otherwise noted Dont try this stuff in my build thread, unless you have 55 years of mechanical OTJ training SAFETY FIRST AS usual, off topic They say your mind goes second, can't remember the first Jim

09-08-2007, 01:31 PM	#1
VinceY Just need a couple more parts. Join Date: Jan 2005 Location: Calgary, Alberta, Canada Posts: 470	Good reason to install headlight relays I have been wanting to install relays on my headlights and finally found the reason for it. The other day I touched the stem on my switch and actually burnt my finger. Normal headlights, by the way. Anyway, the switch felt like it was toasted, so I replaced it this morning and wired in relays. Check out the switch and how fried it was compared to the new one. White bakelight on the new switch instead of chared like the old. Hole melted in the stem. It melted my harness a bit also, picture 2. Attached Images __________________ --------------------------------------------------- 1947 Studebaker M5 project to match the camping trailer. 1950 Chev 4x4 Pickup 1958 Shasta Airflyte Travel trailer (fresh restoration) 1971 C/10 Pickup(Frame off Restoration) 1972 K5 Blazer CST (Daily Driver & My Company Truck) 1976 Honda CB750 Bobber 1988 Jaguar XJ12

09-12-2007, 02:32 PM	#10
Big J Its lookin' like a Blazer! Join Date: Aug 2003 Location: Gods Country, KY Posts: 1,773	Re: Good reason to install headlight relays Looks good to me.... I've been wanting several of those trouble lights for all of my rides.... Nice work.... __________________ BAZINGA! My Build



Register or Log In To remove these advertisements.

Register or Log In To remove these advertisements.