Changing relays (headlight) for a novice - Page 2 - Defender Source
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  #21  
Old May 27th, 2014, 10:49 PM
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Manimal
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Carl Jonsson
1995 NAS D90 #219
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Sounds unnecessarily complicated. I would rewire them so that they are independent of each other. Use the ARB loom for your headlights and get another one for your off road lights. Redundancy means safety. If your headlight circuit goes out you still have another functioning circuit to rely on. It happened to one of our trucks on my last trip. Headlights went out in the dark but luckily they had an independent circuit with 4 roof bar lights.
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  #22  
Old May 28th, 2014, 07:58 AM
Lemonhead
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TB
1997 D90 SW
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It would be odd if your current Hella setup didn't have a relay (though I've seen some odd things done on my truck by PO). Easy enough to use the existing relay and rewire it.


*One hot wire (ignition) to switch
*One wire from switch to relay
*Constant hot to relay
*Ground to relay
*Wire from relay to lights (typically blue on Hella)
*Other wire from lights to ground (typically brown on Hella)

Plenty of wiring diagrams if you google it.

Remove all old wires and start fresh - use minimum 12 gauge for wires going to the lights - 18 gauge fine for others. And make sure there's a fuse on the hot lead.

All above can easily be handled by a mechanic but it's just as easy for a guy in his driveway to do with a little know how and some inspiration. Probably some local guys on the board who wouldn't mind lending a hand/knowledge.

Trickiest part is keeping wires neat and making sure all connections are good (I solder, some swear by connectors). And finding dry location for the relay.

If you take proper precautions - remove ground from battery when you start and put a fuse in line - then the worst that happens if something goes wrong should only be a blown fuse.

Save the "mechanic money" for the big stuff - you'll need it
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  #23  
Old May 28th, 2014, 10:10 AM
Roverlab
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Trevor Griffiths
85 110, 92 110, 92 RR, 06 LR3
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Personally, I use the Hella waterproof relays and waterproof fuse holders from the likes of Rallylights.com and Waytek, as well as stock the correct color wire from British wire to make my own harnesses as needed.
So many generic harnesses come with not qute the right length of wire (ie: too much) that to do the job neatly, you end up trimming and crimping/soldering the correct connectors onto it anyway...
Had a Series 2A in recently that someone had added 20 switches to the dash, a number of relays, used 3 colors of wire and mounted all of the relays in a manner to collect water. Nice general idea, but just not quite enough thought put into executing the job thouroughly. Put the effort in to do it right the first time.....
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  #24  
Old May 28th, 2014, 11:07 AM
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Danny
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Quote:
Originally Posted by Roverlab View Post
Personally, I use the Hella waterproof relays and waterproof fuse holders from the likes of Rallylights.com and Waytek, as well as stock the correct color wire from British wire to make my own harnesses as needed.
So many generic harnesses come with not qute the right length of wire (ie: too much) that to do the job neatly, you end up trimming and crimping/soldering the correct connectors onto it anyway...
Had a Series 2A in recently that someone had added 20 switches to the dash, a number of relays, used 3 colors of wire and mounted all of the relays in a manner to collect water. Nice general idea, but just not quite enough thought put into executing the job thouroughly. Put the effort in to do it right the first time.....
RallyLights.com made me a harness from scratch for much less than the ARB/Painless/etc one using Hella Relays. I measured the lengths from Battery box to Left headlight (up along the framerail), then left to right (leaving slack to go around things) and they made it for me delivered in about a week. It was still working great when I sold the 90. The difference in luminosity/brightness is pretty remarkable.
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  #25  
Old May 28th, 2014, 01:00 PM
Roverlab
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Trevor Griffiths
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I use these:
http://www.rallylights.com/all/elect...h-bracket.html
http://www.waytekwire.com/item/75610...ERPROOF-RELAY/
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