Kenn Oie in Wisconsin asked me about retrofitting H4 headlamps in his Squarebird. H4 bulbs cast a lot more light but it comes at a cost of higher amperage (that our cars weren't designed for). Rather than overloading the headlight switch, we use the headlight switch to turn on relay coils. Then, the relay contacts carry all the load.
The existing plug-in bullet connections are accessible at the fender apron. This is simply a matter of unplugging the HI/LO beam foot switch wires (at the front of the car) and jumper-ing them to turn on relay coils. The relay contacts control the headlight juice by completing the path from the battery to the existing bullet connectors.
I got busy and identified our wire colors and applied them to this two-relay schematic. I put the instructions in the picture.
Kenn suggested a great method for grounding the headlights/horns/parking lights, etc. He drills a hole and adds a long brass screw through the body panel then tightens it with a nut. The rest of the screw protruding beyond the nut is where all the ring terminals connect, then tighten with another nut. One of these on each side of the front will produce a solid ground. - Dave
The existing plug-in bullet connections are accessible at the fender apron. This is simply a matter of unplugging the HI/LO beam foot switch wires (at the front of the car) and jumper-ing them to turn on relay coils. The relay contacts control the headlight juice by completing the path from the battery to the existing bullet connectors.
I got busy and identified our wire colors and applied them to this two-relay schematic. I put the instructions in the picture.
Kenn suggested a great method for grounding the headlights/horns/parking lights, etc. He drills a hole and adds a long brass screw through the body panel then tightens it with a nut. The rest of the screw protruding beyond the nut is where all the ring terminals connect, then tighten with another nut. One of these on each side of the front will produce a solid ground. - Dave
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