headlight relay harness

ezernut9mm · Post by **ezernut9mm** » May 25, 2011, 8:14 am

looks like paul is making another round of harnesses. these are way better than the lmc/made in taiwan harnesses and should be a direct install on 65 and 66 trucks as the under hood is the same as the 67-72.
i mocked one up on my 61 and everything worked perfectly there as well. the only problem i had was the closed headlight bucket design of the 61 would not allow me to fit the assembled harness through the small grommet opening. so i started taking it apart to insert the ends through the grommet and that's as far as i got before giving the harness to greg d to install on his 64.
if you are looking to upgrade your headlights you might look into getting one of these.

http://www.fordification.com/forum/view ... 11&t=58887

Post by **Greg D** » May 25, 2011, 8:32 am

I will soon be posting pics of this as it is installed in my my truck.
I'll post a pic of the harness itself after I get home.

ezernut9mm · Post by **ezernut9mm** » May 25, 2011, 8:07 pm

good deal greg. i think i am going to get one for the uni and have him keep the ends off so i can assemble them once i get the ends through the grommets.

Post by **Greg D** » May 26, 2011, 2:20 pm

OK had a dead camera.
I'll still get a pic up.
The quality & finish of this assembly is first rate BTW!

slickmainer · Post by **slickmainer** » May 26, 2011, 4:08 pm

390nut · Post by **390nut** » May 26, 2011, 5:55 pm

Greg D wrote:OK had a dead camera.
I'll still get a pic up.
The quality & finish of this assembly is first rate BTW!

Thanks for the kudos, Greg. I spent some time developing/redesigning the harness to be clean and tidy and well built.

Yes I am planning another run of harnesses. Figured I would stop in here to get the ball rolling, now that it's been determined what needs doing to make them work on the slicks. It is easy enough to leave the headlight sockets off, and then you would just add the terminals to the headlight sockets during install.

For those of you who don't know, I've been building these harnesses for Ford trucks and other vehicles for about 8 years now. I've sold over a 1000 of them, with only 3 failures in all that time, two of which were installer error, and one was a bad crimp on my part, and I replaced all of them free of charge, minus return shipping. My 2 main designs that I have templates for have been the 67-7 F-series trucks, and the Kawasaki ZRX1100 and 1200 motorcycles, but I have done other vehicle makes as well, including dual headlight bikes, vehices with driving/fog/running lights, and bikes/cars/trucks running other styles of lights (such as 9006/9007 bulbs) so I can pretty much make a harness to order once I have the supplies on hand. Special bulb sockets or parts for variations on the standard harness have to be ordered seperately, but I can make a harness for virtually any lighting need on your older vehicles with the right information from you (and your patience in waiting for it to get made and shipped). I have also done harnesses that turn on driving lights with the low beams, and other variations.

I work full fime, and have a 2 year old from monday to wednesday that takes precedence, and I also would make any standard harnesses before making custom ones (to save time as I make them in batch mode, doing each part of all harnesses at the same time).

Figure 2-3 weeks turn around for a "group buy" (which, unfortunately, I have to do to get rolling again, after that I hope to have the supplies on hand to make them to order)

If there is enough interest (and it's allowed

) I'll put up a seperate "for sale" thread here on this site to help me keep things more organized.

390nut · Post by **390nut** » June 4, 2011, 6:41 pm

Wow, lots of views but no interest?

Figured I would have a question or two, at least.

Uncle Skip · Post by **Uncle Skip** » June 4, 2011, 6:55 pm

Paul.
My problem is that you're just a little late on letting us know. I bought one from Jeg's last January and its sitting on my bench waiting.
If I hadn't already plunked down the cash, I'd be buying one from you.
Sorry bud.
U@ss

ezernut9mm · Post by **ezernut9mm** » June 4, 2011, 8:04 pm

paul, i think once i finally get one installed and people can see the improvement first hand, interest will go up.

unibody madness · Post by **unibody madness** » June 4, 2011, 8:28 pm

Ok
I just found the thread ,so I will ask, what is involved /included and what is the cost. I too have 61 year trucks. pm me if you prefer

390nut · Post by **390nut** » June 4, 2011, 8:59 pm

unibody madness wrote:Ok
I just found the thread ,so I will ask, what is involved /included and what is the cost. I too have 61 year trucks. pm me if you prefer

For full details of what is involved, follow the link in the first post above. For a basic idea, keep reading. Cost is $65.00 shipped.

this harness is virtually plug and play, with the exception that according to Chris (ezernut9mm) the `61 trucks have a different lamp bucket, and the headlight plugs have to be left off for the wires to fit through. You would then push the terminals into the sockets.

Basically you hook up the power and ground, run the harness, plug in the sockets to the headlights, and lastly install the fuse. The harness plugs into one of your OEM headlight plugs to provide signal to the relays, telling them when to turn on and off.

ezernut9mm wrote:paul, i think once i finally get one installed and people can see the improvement first hand, interest will go up.

Here's the quick and dirty info I've posted on Fordification.com, showing the difference on my truck.

This redesigned version utilizes Micro relays, (old version used Mini Bosch-style relays) is both lighter and smaller, and the relays themselves are rated to last longer than the Bosch-style Mini's. I've also made this harness completely from scratch. No more assembled relay holders that I added wire onto using crimp terminals, this entire assembly, from relays to headlight plugs contains only a few terminals. The ones the relays plug into, a splitter for each side, and the headlight plugs themselves. The old version of this harness gave me 11.9 volts to the headlight, (what I got from one harness, anyways) but this one puts 12.3 volts to the headlight. More volts to the bulb means brighter lights!

A couple of pics of the difference in light output on MY truck. Each truck will be different, to some degree, based on condition of your factory wiring and switch, mostly. Keep in mind I am holding the drivers side light (left side in the pics) in my hand, so the aim is a bit "off" Also keep in mind, this shows the output of the original, first harness I made, for my truck. The newer version would be just a tad bit brighter, with nearly a half of a volt more than the older one.

Low Beam

High Beam

ICEMAN6166 · Post by **ICEMAN6166** » June 4, 2011, 9:03 pm

Paul

thats a good price

i also have a 61 but i require that the harness is made with the ability of running both high and low beam at the same time just like the one i made for my 66. how much will this add to the cost if you are willing to do it?

Post by **Greg D** » June 4, 2011, 9:07 pm

Well, my install & pics got sidetracked by packing to move (it's in a box right now).
I'd buy another in a second if I had more than one truck though.
I'm pretty picky about stuff, and have a fair knack for making it up as I go along - I don't think I could duplicate the quality of this for the price. I'd also kill the better part of a weekend doing it.
It looks so good I am going to make the rest of my harness to match the headlight kit.

390nut · Post by **390nut** » June 5, 2011, 8:27 am

Greg D wrote:Well, my install & pics got sidetracked by packing to move (it's in a box right now).
I'd buy another in a second if I had more than one truck though.
I'm pretty picky about stuff, and have a fair knack for making it up as I go along - I don't think I could duplicate the quality of this for the price. I'd also kill the better part of a weekend doing it.
It looks so good I am going to make the rest of my harness to match the headlight kit.

Thanks Greg. I like the durability of the covering on this harness, it's flexible but not flimsy. Holds its shape well, and does a really good job of protecting the wiring.

ICEMAN6166 wrote:Paul

thats a good price

i also have a 61 but i require that the harness is made with the ability of running both high and low beam at the same time just like the one i made for my 66. how much will this add to the cost if you are willing to do it?

Although I don't recommend it, I can do that relatively easy, extra $5 will cover the extra work/parts involved. Been told it kills bulbs faster due to the excessive heat. Makes good sense I guess, but I have no PERSONAL experience so I can't say that as a fact.

i am guessing you just leave the lights in one mode (high or low) and dont switch them except to turn them on and off?

Anyways, shoot me a PM with the same info.

390nut · Post by **390nut** » June 5, 2011, 8:30 am

Had to edit my post above, as I initially misunderstood Chris before. I thought the `64 and earlier trucks had the different headlight bucket with the smaller opening, while it is only the `61.

If you want a harness for a `61, make sure you tell me in PM and also in the paypal message, so I can keep it straight and get you the right setup.

ICEMAN6166 · Post by **ICEMAN6166** » June 5, 2011, 8:51 am

ICEMAN6166 wrote:Paul

thats a good price

i also have a 61 but i require that the harness is made with the ability of running both high and low beam at the same time just like the one i made for my 66. how much will this add to the cost if you are willing to do it?

Although I don't recommend it, I can do that relatively easy, extra $5 will cover the extra work/parts involved. Been told it kills bulbs faster due to the excessive heat. Makes good sense I guess, but I have no PERSONAL experience so I can't say that as a fact.

i am guessing you just leave the lights in one mode (high or low) and dont switch them except to turn them on and off?

Anyways, shoot me a PM with the same info.[/quote]

low stays on when you switch to high but it can be turned off with a switch so i suppose you could call it low, high and extra high.
had no issues with the bulbs.
Alaska is dark in the winter and large creatures roam the roadsides so i want all the light i can get.

jefflovesf250s · Post by **jefflovesf250s** » June 5, 2011, 5:44 pm

390nut: I'm a customer. Send me a PM with your e-mail or telno. I'll call to get payment details. Th. Jeff

390nut · Post by **390nut** » June 5, 2011, 6:49 pm

ICEMAN6166 wrote:low stays on when you switch to high but it can be turned off with a switch so i suppose you could call it low, high and extra high.
had no issues with the bulbs.
Alaska is dark in the winter and large creatures roam the roadsides so i want all the light i can get.

Ok, shoot me a PM!

jefflovesf250s wrote:390nut: I'm a customer. Send me a PM with your e-mail or telno. I'll call to get payment details. Th. Jeff

PM replied to.

Bill W · Post by **Bill W** » June 5, 2011, 7:54 pm

I just sent my payment, Paul.

I look forward to getting mine.

Thanks,

Bill.

390nut · Post by **390nut** » June 6, 2011, 12:53 pm

Got it Bill, thanks.