Introduction: How to Make a Headlight Wiring Relay Kit
this is my first time to post a instructable...
i just want to share my work to everyone...
i hope you will like it....
Warning:::do it at your own risk
better remove your negative battery connection so there will be no damage if you short your connections...
i just want to share my work to everyone...
i hope you will like it....
Warning:::do it at your own risk
better remove your negative battery connection so there will be no damage if you short your connections...
Step 1: Things and Tools That You Need:
things and tools that you need::
30A bosch relay - 2pcs.
relay socket - 2pcs. or spade terminals male(optional if your on budget)
spade terminals - 2 pairs
ring terminals - 2pcs.
auto wire - i use 22ft. of gauge 10 wire or you can use #12 (don't use #13 or #14)
fuse holder - 2pcs. ceramic or plastic and extra 1pc.(optional if you'lll add 2 more lights)
fuse - 10A ,15A or higher than tthese if you'll add more lights
Bulb -all weather or high wattage bulb 100/80w or higher(optional) if you really like much more light like a hid's
bulb ceramic socket(optional) if you have higher wattage bulb or plaining to upgrade.
electrical tape(E.tape)
shrink tube(optional) if you want that to look a pro. work
Solder
solder lead
soldering paste(optional use)
cutter or scissor
long nose or pliers
ballpen or pencil
paper
clear tape
working area
30A bosch relay - 2pcs.
relay socket - 2pcs. or spade terminals male(optional if your on budget)
spade terminals - 2 pairs
ring terminals - 2pcs.
auto wire - i use 22ft. of gauge 10 wire or you can use #12 (don't use #13 or #14)
fuse holder - 2pcs. ceramic or plastic and extra 1pc.(optional if you'lll add 2 more lights)
fuse - 10A ,15A or higher than tthese if you'll add more lights
Bulb -all weather or high wattage bulb 100/80w or higher(optional) if you really like much more light like a hid's
bulb ceramic socket(optional) if you have higher wattage bulb or plaining to upgrade.
electrical tape(E.tape)
shrink tube(optional) if you want that to look a pro. work
Solder
solder lead
soldering paste(optional use)
cutter or scissor
long nose or pliers
ballpen or pencil
paper
clear tape
working area
Step 2:
after you have all the things and tools you will use
now lets make a headlight wiring relay kit:
First study the 3 diagrams that you will use as your guide on how you want to built your wiring..
1.measure the lenght of the wire you need from the stock wiring going to the left to right if your battery is in the right then your wiring should start in right headlamp going to left ..
2.if your battery is in left headlamp start in left going to right headlamp...
3.now prepare your relay socket or terminals and wires.. im using the socket so it will be easy to remove the relay if it's busted or damage...
4. slice the all wire insulation in the relay socket not that to much about 1inch.. about the 87a or the center wire in the relay socket we have no use on it just tape or you can cut it..
5.now cut your auto wire to the length that you needed and one thing make an extra 3inch in your wire before you cut it so you can extend it were you want it to put in...
6.after cutting the auto wire.. slice all one side of your auto wire about 1inch
then the other end is for the terminals..
7.prepare your 2 fuse holder cut the insulation 1inch. tap and twist the two wires from the fuse holder tap then twist it again in the relay socket wire where the 2 power(+)30 is.. connected them then solder and E.tape it or shrink tube then get your ring terminal slice the end of the wire about 1/2inch then crimp the terminal with your crimping tool.. i just use my longnose to do that.. then put some E.tape or shrink tube.
8.now ready your paper and pencil/ballpen to make your label.. write HIGH-IN, HIGH-OUT , LOW-IN , LOW-OUT then cut them... get your clear tape then put it to your cut out label to the designated wire.
9.get your labeled wires with LOW-IN tap and twist it to the coil feed(line-in ,stock wiring) from where your low relay should be then solder and E.tape or use a shrink tube. then the other end of the wire you need the female spade terminal slice your wire about 1/2inch then crimp the terminal with your crimping tool.. i just use my longnose to do that.. then put some E.tape or shrink tube.
10.get your labeled wires with HIGH-IN tap and twist it to the coil feed(line-in ,stock wiring) from where your HIGH relay should be then solder and E.tape or use a shrink tube. then the other end of the wire you need the female spade terminal slice your wire about 1/2inch then crimp the terminal with your crimping tool.. i just use my longnose to do that.. then put some E.tape or shrink tube.
11.get your labeled wires with 2pcs LOW-OUT tap and twist it to the 87(line-OUT) from where your LOW relay should be then solder and E.tape or use a shrink tube. then the other end of the wire you needs the male spade terminal slice your wire about 1/2inch then crimp the terminal with your crimping tool.. i just use my longnose to do that.. then put some E.tape or shrink tube.
12.get your labeled wires with 2pcs HIGH-OUT tap and twist it to the 87(line-OUT) from where your HIGH relay should be then solder and E.tape or use a shrink tube. then the other end of the wire you needs the male spade terminal slice your wire about 1/2inch then crimp the terminal with your crimping tool.. i just use my longnose to do that.. then put some E.tape or shrink tube.
13.now get the wires for NEGATIVE(ground) get the two ends of the wire tap and twist then then add another wire then twist it to the wire then solder then and E.tape then get your ring terminal slice the end of the wire about 1/2inch then crimp then put some E.tape or shrink tube.
14.where almost finish if you already tape your relay socket together to make them a pair that's good.. and now you need to think if you want to pair your fuse to the relay.. like i did it's ok or what better suites you..then your done in your first DIY headlight wiring relay kit.
Question: why do i need a bulb ceramic socket?
Answer: if you have or plain to upgrade your bulbs to a high wattage you need to have this one so it will not melt your OEM plastic socket.. if you are afraid to cut your OEM there is a plug and play ceramic socket that you can buy.
Question: how can i connect my wring relay kit?
Answer: first remove your NEGATIVE battery connection..then if your old wiring is accessible then its good..but if not you need to remove your headlamp just to make way in your wiring if all is ready and you have now an access to your old wiring from the headlamp..
before you remove the 2 terminal that connects your old HIGH/LOW wiring to the bulb. remember or make a label what is or whre your high/low should be connected and dont touch or remove anything else but first put some E.tape on the other side of the terminal where the old wiring is.. you just need the high and low after removing all your old connection. now connect your new wiring kit to the one side of your old or stock wiring.. remember that your coilfeed(LINE-IN) is the one with a female terminal now connect your female terminal to the male then E.tape them then connect your LINE-OUT for HIGH/LOW going to the bulb then the same to the other side of your headlamp..now connect your positive#30 wire to the positive battery then the NEGATIVE wire from the relay going to the body/chasis or negative battery then test it if you get the correct connection..
after you confirm that you have the right connection and your done..
Now get a can of soda enjoy your work because you did a great JOB!!!!
now lets make a headlight wiring relay kit:
First study the 3 diagrams that you will use as your guide on how you want to built your wiring..
1.measure the lenght of the wire you need from the stock wiring going to the left to right if your battery is in the right then your wiring should start in right headlamp going to left ..
2.if your battery is in left headlamp start in left going to right headlamp...
3.now prepare your relay socket or terminals and wires.. im using the socket so it will be easy to remove the relay if it's busted or damage...
4. slice the all wire insulation in the relay socket not that to much about 1inch.. about the 87a or the center wire in the relay socket we have no use on it just tape or you can cut it..
5.now cut your auto wire to the length that you needed and one thing make an extra 3inch in your wire before you cut it so you can extend it were you want it to put in...
6.after cutting the auto wire.. slice all one side of your auto wire about 1inch
then the other end is for the terminals..
7.prepare your 2 fuse holder cut the insulation 1inch. tap and twist the two wires from the fuse holder tap then twist it again in the relay socket wire where the 2 power(+)30 is.. connected them then solder and E.tape it or shrink tube then get your ring terminal slice the end of the wire about 1/2inch then crimp the terminal with your crimping tool.. i just use my longnose to do that.. then put some E.tape or shrink tube.
8.now ready your paper and pencil/ballpen to make your label.. write HIGH-IN, HIGH-OUT , LOW-IN , LOW-OUT then cut them... get your clear tape then put it to your cut out label to the designated wire.
9.get your labeled wires with LOW-IN tap and twist it to the coil feed(line-in ,stock wiring) from where your low relay should be then solder and E.tape or use a shrink tube. then the other end of the wire you need the female spade terminal slice your wire about 1/2inch then crimp the terminal with your crimping tool.. i just use my longnose to do that.. then put some E.tape or shrink tube.
10.get your labeled wires with HIGH-IN tap and twist it to the coil feed(line-in ,stock wiring) from where your HIGH relay should be then solder and E.tape or use a shrink tube. then the other end of the wire you need the female spade terminal slice your wire about 1/2inch then crimp the terminal with your crimping tool.. i just use my longnose to do that.. then put some E.tape or shrink tube.
11.get your labeled wires with 2pcs LOW-OUT tap and twist it to the 87(line-OUT) from where your LOW relay should be then solder and E.tape or use a shrink tube. then the other end of the wire you needs the male spade terminal slice your wire about 1/2inch then crimp the terminal with your crimping tool.. i just use my longnose to do that.. then put some E.tape or shrink tube.
12.get your labeled wires with 2pcs HIGH-OUT tap and twist it to the 87(line-OUT) from where your HIGH relay should be then solder and E.tape or use a shrink tube. then the other end of the wire you needs the male spade terminal slice your wire about 1/2inch then crimp the terminal with your crimping tool.. i just use my longnose to do that.. then put some E.tape or shrink tube.
13.now get the wires for NEGATIVE(ground) get the two ends of the wire tap and twist then then add another wire then twist it to the wire then solder then and E.tape then get your ring terminal slice the end of the wire about 1/2inch then crimp then put some E.tape or shrink tube.
14.where almost finish if you already tape your relay socket together to make them a pair that's good.. and now you need to think if you want to pair your fuse to the relay.. like i did it's ok or what better suites you..then your done in your first DIY headlight wiring relay kit.
Question: why do i need a bulb ceramic socket?
Answer: if you have or plain to upgrade your bulbs to a high wattage you need to have this one so it will not melt your OEM plastic socket.. if you are afraid to cut your OEM there is a plug and play ceramic socket that you can buy.
Question: how can i connect my wring relay kit?
Answer: first remove your NEGATIVE battery connection..then if your old wiring is accessible then its good..but if not you need to remove your headlamp just to make way in your wiring if all is ready and you have now an access to your old wiring from the headlamp..
before you remove the 2 terminal that connects your old HIGH/LOW wiring to the bulb. remember or make a label what is or whre your high/low should be connected and dont touch or remove anything else but first put some E.tape on the other side of the terminal where the old wiring is.. you just need the high and low after removing all your old connection. now connect your new wiring kit to the one side of your old or stock wiring.. remember that your coilfeed(LINE-IN) is the one with a female terminal now connect your female terminal to the male then E.tape them then connect your LINE-OUT for HIGH/LOW going to the bulb then the same to the other side of your headlamp..now connect your positive#30 wire to the positive battery then the NEGATIVE wire from the relay going to the body/chasis or negative battery then test it if you get the correct connection..
after you confirm that you have the right connection and your done..
Now get a can of soda enjoy your work because you did a great JOB!!!!
Step 3: Photo's Updated
