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Always Be Fixing Cars
 
Join Date: Nov 2012
Location: SE CT
Posts: 1,629
964 Headlight Relay Kit - no-cut, plug-n-play - taking interest

Hi all

I designed a H4 relay kit for my car, intended to be as invisible, high quality and Porschey as possible. In doing so I learned a lot and invested a ton in tooling, terminals and skills. I think it may be of use to others so I'm posting to poll interest. Thanks to the community here for help along the way.

The kit is entirely integrated with Central Electrics aka frunk mounted fuse box. I activated empty fuse and relay positions. No factory wires are cut or vampired whatsoever. Two factory wires are de-pinned to serve as triggers. Using a supplied tool, these are removed intact and can be reconnected if you want to go concourse. There are no externally visible components. I wanted to avoid the frunk-clutter common to these installs such as relays mounted on brackets, in line fuses or new connections to the battery. All wiring runs in black abrasion resistant sheathing and follows existing runs, re-uses existing grommets. Ceramic H4 terminals are included. If you are planning to swap from H5>H4, this will save you ~$30 for the adapters you'd need. Factory headlight connectors are abandoned intact, in the buckets. The kit uses 12ga wiring for high beams and 14ga for low. This is to save weight and make the wires easier to pass thru grommets (the most annoying part of the install). I plan to run 80/100w bulbs but see no reason the brave (and well aimed) couldn't go to 100/130. Different gauge wiring may be available by request.

Cost before shipping will be approx $155 or $125 without the de-pinning tool. I strongly recommend the tool, it is quite specialized and I do not believe a generic would do. Detailed install instructions will be included and every wire is labeled using factory nomenclature. The only special tool you need to supply is a generic open-barrel non-insulated terminal crimper. This is to allow the headlight wiring to enter the buckets without terminals crimped on. If you don't own one I'll recommend an inexpensive ~$30 option.

The kit looks simple but is made of a dizzying array of parts all of which are either Genuine Porsche, TE/AMP or Molex. The good stuff. Sourcing is a pain so I'm taking interest now to stock up for ~Jan/Feb shipping. PM your email and shipping address to be added to my first-come list.

Photo of prototype. long runs to headlight buckets not shown and will be encased in abrasion resistant sheathing.

__________________
'91 964 C4 - New Daily
'73 Alfa GTV - 90% done 50% to go
'65 912 - Welding in process
Old 01-15-2021, 08:45 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #1 (permalink)
Always Be Fixing Cars
 
Join Date: Nov 2012
Location: SE CT
Posts: 1,629
Here's how the fusebox looks after the install. Relay 61 and 62 are low and high beams respectively.


__________________
'91 964 C4 - New Daily
'73 Alfa GTV - 90% done 50% to go
'65 912 - Welding in process
Old 01-18-2021, 05:29 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #2 (permalink)
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