HD Headlight Harnesses w/ 4 High Mod

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5vortec7

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Hey Brian,

Have any ideas on mounting this waterproof relay box with the dual battery setup? I have a 96 suburban 7.4 vortec.. there's not much space to do much of anything under this hood..

I got my kit about a year ago and was going to tackle it today.. but I'm thinking the second battery will likely interfere with the big waterproof box on the driver side fender well. The kit is awesome btw, just seeking some input and advice on where I should mount this.

Would it make any difference mounting it on the passenger side? I'm considering modifying the factory filter box and mounting it to that then wiring direct to the battery.
I have the same vehicle, with dual batteries, just a ‘99. I have the original version harness though and it does fit underneath the pcm, not sure if the marine grade box will fit. If it doesn’t, there is no problem mounting on the passenger side, just use the passenger side stock connectors instead of drivers side as instructions say.
 

kami

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Here’s my version of the HD headlight harness. Delivers a full 12v to headlights through 12 awg wires. 4 high mod keeps low beams on with high beams.

Made with all new materials, all connections crimped and soldered, ceramic headlight plugs, 30 amp inline fuses, 4 relay block with moveable mounting tabs and cover (one empty slot left available for any future need). Wires are long enough to enable a variety of mounting locations, including 3 foot 12v supply and ground wires.

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Cost is $175 plus shipping. I can ship orders within a week of payment. Accepting PayPal (3% fee added) and Venmo (no fee). If interested post here, leave payment choice along with zip code for shipping and I will send a pm to you with final cost estimate. Thanks for your support and please feel free to contact me with any questions or feedback.
1992 chevy k2500, very interested in the harness. Venmo, 32571
 

NickP

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I just completed the installation of Brian’s 4 light harness. The directions I received suggest that it’s possible to do the install w/o removing the grill, which it could be , but I elected to remove the grill (10 screws) in order to get a very tidy install making sure I secured all the wiring So it looked as stock as possible. I ended up securing the new wiring harness to the existing harness with zip ties along the front of the truck, behind the grill.

I also wanted to hide the waterproof box that hold the relays under the ECM and found out it was a tight fit. In retrospect, I don’t think I needed the waterproof option. After all, the relay box is under the ECM which is under the hood (And I live in San Diego where it rarely rains, except this past month!) I did not use the supplied mounting brackets. Instead, I used 4 adhesive backed foam cylinders to slightly elevate the box but it took a lot of maneuvering to find a position for the box that would also allow me to properly secure the ECM as it was prior to sticking that bulky box underneath it.

I ran the power (+) side cable to the fuse-relay center near the firewall and I found a suitable place for the ground (-) cable. The entire install was straightforward and pretty easy.

Finally, I had a 3M headlight restoration kit which I used to restore my original headlights. Man, what a difference. This kit provide a Velco faced disc pad holder and sandpaper staring with 500 grit then 800, 3000 and finally a buffing pad with polishing compound. My headlights and turn signals look like crystal jewelry now.

The results are worth the skinned knuckles and effort. The low beam output is noticeably better and the 4 light modification is also very worthwhile making night driving feel a whole lot safer. Sorry I did not take any photos.

Nick
 

Caman96

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I just completed the installation of Brian’s 4 light harness. The directions I received suggest that it’s possible to do the install w/o removing the grill, which it could be , but I elected to remove the grill (10 screws) in order to get a very tidy install making sure I secured all the wiring So it looked as stock as possible. I ended up securing the new wiring harness to the existing harness with zip ties along the front of the truck, behind the grill.

I also wanted to hide the waterproof box that hold the relays under the ECM and found out it was a tight fit. In retrospect, I don’t think I needed the waterproof option. After all, the relay box is under the ECM which is under the hood (And I live in San Diego where it rarely rains, except this past month!) I did not use the supplied mounting brackets. Instead, I used 4 adhesive backed foam cylinders to slightly elevate the box but it took a lot of maneuvering to find a position for the box that would also allow me to properly secure the ECM as it was prior to sticking that bulky box underneath it.

I ran the power (+) side cable to the fuse-relay center near the firewall and I found a suitable place for the ground (-) cable. The entire install was straightforward and pretty easy.

Finally, I had a 3M headlight restoration kit which I used to restore my original headlights. Man, what a difference. This kit provide a Velco faced disc pad holder and sandpaper staring with 500 grit then 800, 3000 and finally a buffing pad with polishing compound. My headlights and turn signals look like crystal jewelry now.

The results are worth the skinned knuckles and effort. The low beam output is noticeably better and the 4 light modification is also very worthwhile making night driving feel a whole lot safer. Sorry I did not take any photos.

Nick
What about relay or fuse replacement in the marine grade box? Would you have to lift ECM up?
 

NickP

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What about relay or fuse replacement in the marine grade box? Would you have to lift ECM up?
Yep, the ECM needs to be moved out of the way to access the relay box lid. The only other mounting option I could see was on the fender wall but I would lose the storage box and I wasn’t willing to do that. From the photos Brian posted here I‘d bet there is room to mount the standard relay box on the fender wall (or someplace else) and still have room for the storage box.
 

caw_86

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Question, after installing everything, you are left with an empty socket on the passenger side, anyone have any creative ideas of what they converted it to power
 
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