HD headlight harness (by @5vortec7) install today!

[RichardSwinger]

This is probably the first time I finished a project on this truck in one shot. Like all projects with this thing, there were roadblocks but I was surprisingly able to get through them and get everything back together. Ordered the HD 4-Hi harness from @5vortec7 and it was surprisingly sturdy and well put together. The problems I had putting it in were 100% because of the cheap O'Reilly's headlight housings and having trouble taking them out and fixing them up to put back together again. I'm going to make a few separate posts with pictures and explanations to help this thread flow a bit better...

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[RichardSwinger]

I took the whole grille off for ease of access. Routed the harness and followed the stock wiring. I had a hard time disconnecting the stock wires from the lights but got them out without breaking anything eventually (in hindsight I should have just removed the light housings to begin with, more on that later). The passenger side outputs don't get used, so I packed them with dielectric grease, taped them up, and zip tied them for good measure.

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[RichardSwinger]

The ceramic male ends of the new harness were super nice and sturdy buy VERY hard to plug in, it probably didn't help that I've got HIR1 and HIR2 bulbs. I didn't want to beat on the bulbs too bad so I decided to remove the whole light housing. That was the the hardest part of the whole job. The brass threads are just poorly press fit in there (and I probably torqued the two top pins in too tight) and they had pulled through making it extremely difficult to get the housings out. I eventually got the housings out without breaking anything, super glued the bottom rim, pressed them back in with channel locks and super glued the top rim. I used some aluminum anti-seize grease on the pin threads and threaded each one to keep the threads free of super glue. When I put the housings back in I didn't gronk down on them, just made them snug.

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[RichardSwinger]

The ground wire spot was easy: there was a ground wire to nowhere for the aux battery that I have wires for but didn't come with the truck when I bought it. Took off that ground wire and put the light harness ground in it's place. The aux battery tray makes a great spot to put the relay block as well. I've got it in there SUPER redneck with mini bungee cords but I was pressed for time and had to leave for work soon. If I ever decide to put the aux battery in, the open space below the ECU is a great option, but for now I like having easy access to the relay block. I'll probably screw the block into the battery tray and ditch the bungee cords... Maybe. But probably not. I call this truck Mad Max for a reason.

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[RichardSwinger]

First picture is low beams. Second is the 4-Hi Low+Hi beams. It's absolutely bonkers. This is the darkest part of my drive to/from work in backwoods middle of nowhere Midlands of South Carolina. With the HIR bulbs and the harness with the 4-Hi I've now got no need for a light bar. Extremely happy I sent some random dude from the forums my money. I know there are other options to get the 4-hi to work, but what Brian puts together is really nice, really easy to install, and I've got full confidence in the quality and design of his wiring.

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[5vortec7]

Damn man, nice write up! I appreciate it and your business.

 

[RichardSwinger]

Damn man, nice write up! I appreciate it and your business.

When you get caught up I need you to make a 4-hi-horn harness for the extra pair of horns I rednecked together [emoji23]

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[gblotter]

What do the PIAA horns give you that the stock horns did not?