Daniel Stern headlight relay assembly kit

[rapandi]

Hi team

 

I bought my Relay kit from Daniel. Looks very comprehensive with all good quality parts. All I need to do is provide my own wires and tools and assemble the harness. 
 

There is a lot of great instructions on Daniels website regarding relays etc. and I have had email correspondence with Daniel regarding building the harness etc. 

 

I have searched the forum in the hope I can find someone who may have documented the process of putting together this kit but I haven’t been overly successful. Has anyone documented this? If so could someone kindly point me to that post please? 
 

I merely want confirmation that what I am doing is correct. 
 

any assistance is greatly appreciated. 
 

regards

 

raj

[Mike A]

I thought it came preassembled , harness and all connectors. Did you not want to go the plug and play route?

[rapandi]

Just now, Mike A said:

I thought it came preassembled , harness and all connectors. Did you not want to go the plug and play route?

 

Hi Mike, I don't have the complete harness. I got the individual parts kit which I am in the process of assembling. 

[Mike A]

Well then....avoid using the Stacon connectors....solder and shrink tube

[Mike Self]

Raj, what year is your car, and what headlight circuit are you trying to insert the relay--low or high beams?  Late cars already have a relay for the high beams, but not roundies.  

 

Long before Daniel Stern came up with his relay kit, I installed a relay for the high beams on my '73.  I did a column about it, so if you think that might help, PM me and I'll send you a copy.

 

mike

[rapandi]

 

4 minutes ago, mike said:

Raj, what year is your car, and what headlight circuit are you trying to insert the relay--low or high beams?  Late cars already have a relay for the high beams, but not roundies.  

 

Long before Daniel Stern came up with his relay kit, I installed a relay for the high beams on my '73.  I did a column about it, so if you think that might help, PM me and I'll send you a copy.

 

mike

Hi Mike,

 

I have 1972 2002 tii RHD roundie. Mine definitely does not have a high beam relay. I am keen to get my hands on that column you wrote - I will send you a PM now. Daniel's kit has come with relay's for both the high and low beams.

[rapandi]

This is a screen shot from daniel stern's website. https://www.danielsternlighting.com/tech/relays/relays.html

 

The bit that I am unsure about are those two yellow highlighted wires which come from the the dip switch to the relays. Do I have to identify the wire for the high and low beam and then splice a wire to each of them and run it to the relays?

 

[M3M3]

Yes.   Find the power wire at the headlights and route it to the relays instead.

[ray_]

1 hour ago, mlytle said:

Yes.   Find the power wire at the headlights and route it to the relays instead.

And the way the RallyLights relay kit does this is with a plug that accepts one of your headlamp plugs (see bottom of pic).

 

Cheers,

Edited March 27, 2020 by ray_

[jgerock]

 Both of my 2002’s have the H4 wiring harness and relay kit from Susquehanna Motorsports.  Tii has relays on the left side, 69 configured with relays on the right side.  Highly recommended!  Easy installation with no wiring modifications.  

[AustrianVespaGuy]

Probably more details than you *need,* but should also cover everything you need to know and then some!

 

[Stu]

I just installed the Daniel Stern relays in my '70, 2 relays, for low and high beam.  You need only intercept the low beam and high beam wires in the wiring loom where you want to mount the relays.  The attached photo shows where I located mine.

Low beams are a single yellow/black and/or yellow/blue wire.  High beams are the 2 thinner white wires in the loom.

You want to interrupt those wires, and the side coming from your headlight switch now becomes your relay trigger (#85), and then #86 gets grounded.  For the low beams, you just interrupt the single yellow wire.  For the high beams, both wires (twisted together as a single wire) go to and from the relay, same as the low beams.

The side of the wire going to your headlights will be the relay out (#87), and  #30 to the positive battery terminal.

pm me with any questions or more photos if you want.

Stu.

 

 

 

 

 

 

[TobyB]

What Stu said.  

 

You're substituting low- current relays for high- current lamps.

 

What does Mr Stern use for fuses?  

 

Since I've been working on my tow rig, I used the OBS Ford trailer relay socket,

which has 2 relays and some nice heavy wires pre- landed.  But still needs 2 fuses.

Maybe I'll go browsing at the junkyard tomorrow to see if I can find something OEM that has a few fuses.

 

t

likes plug- in relays for easy replacement and troubleshooting.

[Stu]

1 hour ago, TobyB said:

What does Mr Stern use for fuses?  

 

 

Here are the fuses.  You can see them in the photo in my earlier post, from the relays to the battery.  With the relays mounted where they are, the fuse wire is long enough.

[rapandi]

Hi Team

 

I spent today building this relay harness. I got it all finished and did a dry fit in the car using cable ties. I used 12 AWG wire for the headlights. I didn’t realise how bulky the harness would be. Pics below. 
 

I will wrap it up like the factory harness once I am happy with it (tomorrow most likely). 
 

Regards

 

Raj