H4 Headlight Wiring Harness

[shikzachaser]

At the request of a member I have recreated the wiring harness I use in my 84 944 for 55 / 100 H4s. The harness cuts no stock wires, bypasses the stock wiring for the high current side, and is fused seperately for high and low beams. If any of you are running these lights through the factory wiring you are asking for trouble long term. In addition you are not realizing the full light output.



After installing the new lights take off the factory jumper that connects to the old lights. I use the OE connector on the driver's side to trigger two 30Amp relays. The factory wiring only provides power for the relay contacts.



It doesn't look like much laying on the floor but simplicity is a good thing. I just realized it is sitting backwards on the floor. When running the harness the fuses and triggers go to the driver's side.



Standard 30 Amp Bosch automotive relays work great. In final form I will be using molex connectors verses the push terminals.



Two fuse holders 1 high / 1 low beam



Fuse holders connect to the back of the alternator. Make sure you disconnect the battery before starting any of this.



The relays tuck into the slots that are up high in the nose. The only thing visible is the ground wire.



The harness has new connectors that plug directly into the lights. Make sure you tape up the stock wires on the passenger side as they are not used and are still hot when the lights are on.

I'll make you the first one Kyle and get it out to you in the next week or so.

Anybody else interested I could probably reproduce them and ship them out for $100 or so. It definately takes a couple hours to make one and I know I will be answering a lot of questions about installation. It's not terribly difficult but it does take some time to do it right. Otherwise feel free to copy mine if you like, it definately works.
Steve

[Mike B]

Nice write up Steve...reminds me of Iceshark (Dan Wray) who was an electrical guru and a true Porsche enthusiast...Keep up the great work!

[Wipeout]

Nice, Steve. About how much does making one run (especially if it costs about $150 to buy one already made...).

[shikzachaser]

There's maybe $40-$50 in materials to do it right. Obviously that does not include the lights.

It's really just a couple good relays, some crimp on terminals (I solder them too and then use heat shrink), a few molex connectors, a couple fuse holders, and some time. It's definately better than running that kind of current through the stock electrical system, plus the lights are way brighter. I have not seen the Ice-Shark version but this is not splitting atoms we are dealing with here, I'm sure it's a good product.
I am just a garage hack.
Steve

[TurboFoFo]

thanks a lot Steve! I just purchased the Hella H4 upgrade from Pelican and bought some piaa 55/100 haven't hooked them up yet as I was looking for something like this. Don't be surprised if I ask you questions.... : )

[IXLOR8]

Steve

What do you think of the kit at Summit? About $32.

I fabricated the like system for my sons car. It cost me about $55.

[toolboy62]

What gauge wire is that Summit kit? I suspect that that is only 16 AWG or so, if you're going to go all out you really ought to go with 12 AWG or 10 AWG to get the full benefits of the relayed goodness.

I have the IceShark kit in my 944. It is awesome. Sadly Dan Wray is no longer with us. I'm actually waiting for the garage to warm up right now so I can go out and finish up the install of E-codes and a similar relay harness in the girlie's Corrado, so you can see I'm a big believer in them. The difference between stock and a good relay harness is astonishing, and the difference between stock headlights and E-codes is equally astonishing (especially on a Corrado, but the stock sealed beams on the 944 were pretty bad.)

nate

[legion]

I paid $150 for the RennBay kit. I'm very happy. I used to avoid driving my car at night becaue the headlight visibility was so poor, now I look forward to it.

[IXLOR8]

legion

What H4 bulbs did you use? Wattages? Did you have to adjust your headlights again? How was the pattern different? Distance?

[shikzachaser]

That looks like a very nice job on the harness IXLOR8. I have never seen the Summit one. I used 10ga from the Alternator and also for the primary grounds. The feeds to the bulbs are 12ga. The 55 / 100 bulbs really light it up. The pattern is much wider and whiter. The high beams light up at least an additional 50 yds brightly. I have poor night vision and have always upgraded the lights on my cars.

Steve

Steve

[legion]

Originally posted by IXLOR8
legion

What H4 bulbs did you use? Wattages? Did you have to adjust your headlights again? How was the pattern different? Distance?

I actually used Sylvania Silverstars. I didn't purchase the adapters for using H4s, though I may at some point. I simply installed the new harness with the existing headlights, and they went from unusably dim to incredibly bright. I don't recall the exact wattage I'm using, but it isn't anything over the top.

[Eldorado]

Thanks Steve, let me know when to deposit via paypal...

I'll be doing a full writeup of the install process as well as pictures.. before and after pics for sure with the cheap ebay lights that the PO installed.. as well as some new H4's..

[shikzachaser]

K..Y..L..E..A..K..A..E..L..D..O..R..D..O..

The harness is in progress, serial # 1. I am making it really nice and pretty for you. I'll try to get it out this week. I found the right connectors so it will be "plug and play" for you. PM your mailing address please so that it goes to the right place. I'll forward my phone iinfo w/ the "kit" so that together we can get it installed. I will make rudimentary instructions and would love feedback on how to improve the directions.
I think you will be pleased, if not don't pay me. I will send an invoice for the cost to make the first one plus postage to Canada.

Steve

[vbaron]

shikzachaser:

With what do you wrap the harness? Is it shrink tubing or some type of tape?

Thanks,
Vin

[Eldorado]

bingo bango bongo

check your PM's in a couple mins, Steve..

[Wipeout]

Steve, I might be willing to guinea pig another one if you're making these for people. If you're not making more, I'll wait for Kyle's write-up and see if I can emulate the two of you.

[shikzachaser]

All connections are soldered, taped, shrink tubed, then it all goes into a braided loom. All power wires are 10Ga to the relays, 12 ga to the lights.

This is the one you get Kyle. I snuck outside to the garage after Mrs 944 went to bed. It's 8 degrees here outside, 70 in the garage w/ radiant heat in the floor and Sport's Center on in the background. All I have to do to finish it is get better connectors to attach to the headlights. The ones on now are so tight it's really easy to bend the pins on the bulbs. I personally just bought H4s and used 55 / 100 bulbs. They are way bright, you will see the Mooses (Meese?) long before they can jump in front of you.



Sorry about having a BMW hood in the pic.







There, that's a proper background. It may be one and done for me as it takes a couple hrs to make one and I do have a life, despite how much I post on this forum.

Steve

[pozican]

wow, those look impressively clean and professional.

Props!

[IXLOR8]

Steve

How much is the harness and shipping to 53589 WI?

Rick

[shikzachaser]

IXLOR8:

Your harness looks as good as the one I made. Where did you get the connectors to plug into the light? I can't find any @ local electrical supply outlets that fit right.

POZICAN:

It's still a little crude. I may make another one to send out that has a bit cleaner look. It does work good though. If I do make more I can definately get them where they look "professional". I guess if I get any money for one it would also elevate it from "amateur" to "professional" just by definition.

Thanks:

Steve