Headlight PnP external harness

[GoldPanther]

Hello, as my first contribution to this forum I want to share this thing a came up with.

I created an external relay harness using the OEM connectors that plug in to the headlights housing and not ordinary 9007 plugs connectors.
My idea was to avoid drilling the rear cover of the housing and not having to remove the headlights for installation. This harness will just PnP

I grabbed the OEM connectors from a donor at the junk yard, got new pins to go with it. here's some pics of the process.
http://i1290.photobucket.com/albums/b525/goldpanther/Mobile%20Uploads/20150119_213049_zpskqmiqhkm.jp g (http://s1290.photobucket.com/user/goldpanther/media/Mobile%20Uploads/20150119_213049_zpskqmiqhkm.jp g.html)
http://i1290.photobucket.com/albums/b525/goldpanther/Mobile%20Uploads/20150128_162629_zpsrcfhbb2z.jp g (http://s1290.photobucket.com/user/goldpanther/media/Mobile%20Uploads/20150128_162629_zpsrcfhbb2z.jp g.html)
http://i1290.photobucket.com/albums/b525/goldpanther/Mobile%20Uploads/20150302_194649_zpshxvowpze.jp g (http://s1290.photobucket.com/user/goldpanther/media/Mobile%20Uploads/20150302_194649_zpshxvowpze.jp g.html)
http://i1290.photobucket.com/albums/b525/goldpanther/Mobile%20Uploads/20150309_200618_zpsrjv3njco.jp g (http://s1290.photobucket.com/user/goldpanther/media/Mobile%20Uploads/20150309_200618_zpsrjv3njco.jp g.html)
http://i1290.photobucket.com/albums/b525/goldpanther/Mobile%20Uploads/20150309_210137_zpsevfzpn3i.jp g (http://s1290.photobucket.com/user/goldpanther/media/Mobile%20Uploads/20150309_210137_zpsevfzpn3i.jp g.html)
http://i1290.photobucket.com/albums/b525/goldpanther/Mobile%20Uploads/20150310_180818_zpskijxoa4c.jp g (http://s1290.photobucket.com/user/goldpanther/media/Mobile%20Uploads/20150310_180818_zpskijxoa4c.jp g.html)
http://i1290.photobucket.com/albums/b525/goldpanther/Mobile%20Uploads/20150318_172058_zpsvc7fkock.jp g (http://s1290.photobucket.com/user/goldpanther/media/Mobile%20Uploads/20150318_172058_zpsvc7fkock.jp g.html)
http://i1290.photobucket.com/albums/b525/goldpanther/Mobile%20Uploads/20150318_172058_zpsvc7fkock.jp g (http://s1290.photobucket.com/user/goldpanther/media/Mobile%20Uploads/20150318_172058_zpsvc7fkock.jp g.html)
http://i1290.photobucket.com/albums/b525/goldpanther/Mobile%20Uploads/20150430_210641_zpsyjn97ruu.jp g (http://s1290.photobucket.com/user/goldpanther/media/Mobile%20Uploads/20150430_210641_zpsyjn97ruu.jp g.html)
http://i1290.photobucket.com/albums/b525/goldpanther/Mobile%20Uploads/20150430_214749_zpsx7ndug3d.jp g (http://s1290.photobucket.com/user/goldpanther/media/Mobile%20Uploads/20150430_214749_zpsx7ndug3d.jp g.html)
[URL=http://s1290.photobucket.com/user/goldpanther/media/Mobile%20Uploads/20150501_001950_zpssaa44vgi.jp g.html]

[GoldPanther]

http://i1290.photobucket.com/albums/b525/goldpanther/Mobile%20Uploads/20150501_002144_zpsmtcsxgqw.jp g (http://s1290.photobucket.com/user/goldpanther/media/Mobile%20Uploads/20150501_002144_zpsmtcsxgqw.jp g.html)
http://i1290.photobucket.com/albums/b525/goldpanther/Mobile%20Uploads/20150626_235636_zpsul2ni2xz.jp g (http://s1290.photobucket.com/user/goldpanther/media/Mobile%20Uploads/20150626_235636_zpsul2ni2xz.jp g.html)
http://i1290.photobucket.com/albums/b525/goldpanther/Mobile%20Uploads/20150318_172321_zpsnbkhjd9h.jp g (http://s1290.photobucket.com/user/goldpanther/media/Mobile%20Uploads/20150318_172321_zpsnbkhjd9h.jp g.html)

I used 14g wire all around, all new pins and weather terminal ends, 40a genuine bosch relays and ceramic relay sockets.
This project turned out so good that I have helped over 8 people on fb pages and other forums macking a harness for them.

[fastblackmerc]

This combined with my LCM repair = never fail headlights!

[GoldPanther]

Yes, that would be like the ultimate headlight upgrade ever!

[cat in the hat]

What does it do ? (I'm a dope :o )

[ctrlraven]

Stock halogen headlight bulbs need to see 12.8 to 13.2 volts to fire properly. The stock wiring limits the voltage due to distance it has to travel (battery to relay box to lcm then back to the headlights), with the upgrade harness it pulls power directly from the battery and uses the factory wiring power wire as a remote turn-on while power and ground are supplied with from a thicker gauge wire at a MUCH shorter distance.

It will basically make your halogen headlights a lot brighter and take a lot of strain off of the relay in the LCM that tends to die that controls the headlights.

[GoldPanther]

^ what he said!
Inside the LCM their is a weak relay which is a 10 amp relay that powers both low beams, the stock wiring is also too thin, 18 gauge wire.
This is why it's super common for the LCM to fail. The LCM costs about $300-500 new.
Fastblackmerc and some other people have the knowledge to fix this issue by replacing the internal relay with a 30a relay. Doing this is an excellent option, but still the original wiring (18g) is still a restriction.

[Esilar]

What happens to the DRL? I think these are running on a pulsed current from the LCM with an lower light output.

[GoldPanther]

What happens to the DRL? I think these are running on a pulsed current from the LCM with an lower light output.

Yes, you are correct! As far as I know the DRLs are used thru the the high beams. This means that the LCM sends a lower voltage to the high beams in order to not wear out the low beam filament.
This can be easily fix by just letting alone the high beam and just bypassing it. And only relay the low beams.
People who had used external relay harnesses on DRL panthers they stopped working and other occasions it made the high beams go full power. My theory is that the low voltage sent is not enough to activate the external relay, in some other cases it actually turns on the external relay, then blinding everyone!