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Upgrade headlight wiring

J joelabraham

This afternoon I completed another modification-one that many of you have done. I purchased a pre made headlight  harness from Painless that Gordon N. had recommended awhile back. It is well made-comes completely assembled with 2 relays, a fuse holder, headlight plugs,  power take off plug and wiring and terminals for the battery-covered with  flexible plastic conduit. The only mod. I had to do was grind down  the power take off  receptical  with a die grinder because my  power plug was right angle-10 minutes and it snapped together. I had to make about 1 inch holes in the headlight buckets to get the plugs thru but I filled them with bondo. I then sealed everything with clear silicone. There was plenty of room in the battery box for the relays and fuse so everything is hidden. Hi and low beams work perfectly and are much brighter.

I am ready  for Carlisle 2016.

Joel

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J joelabraham

LFEPARDO,

The harness kit that I used is  made by www.painlesswiring.com .The # is 30815 but it states"This harness will not work with some factory 90 degree headlight connectors.Contact the Tech dept. 800-423-9696 for assistance." I ran into this problem but solved it by carefully grinding a male and female connector  until they snapped together. They may be able to supply a different connector.The chinese harness that TAB used looks similar and the price is about 1/9 the  the price that I paid.There is plenty of room in the buckets for the connectors and wiring.I used masking tape to hold the rubber gaskets in place when I reassembled the headlights.Good luck.

Joel

El FrazooEl Frazoo Supporting Member

Sounds like about what I did recently with about $20 worth of parts from Autozone and a few hours of fussing.  Can't believe how much voltage/current was lost to the headlights by going through the dash switch. It was like I was burning a single candle in each bucket when on: one with a wick and wax.  Now, I can actually see with just the regular headlights.  Add high beams and the driving lights, and I turn night into day.

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