Headlights Relay for 1979 Fiat

[cyberborikua]

Hey, Spider 2081, I agree w u about doing whatever works best for you, but keeping it as low cost as possible. In my case, to make it easier and cleaner, Im planning on using the SAE connector type to marry them with the OEM ones. Easier and faster that way.

[maxdog]

To clarify my first post :
The power supply to the relays comes from the alternator post via a 30 amp in line fuse.
Each relay is grounded using the existing ground terminal block near the driver's side head light
I disconnected the single wire INPUTs to the main beam and dipped beam fuses in the original fuse box ; and used this to provide a feed to activate each relay via a new jumper wire .
The light switch ,dip switch and original wiring to the fuse box now provides the low power feed to pull in the relevant relay.
I connected the power out put terminal from each relay back to the single wire INPUT terminals in the fuse box with a new 12G jumper .
To summarise
The power to the head lights flows from the alternator post , through the in line fuse to the relays and on to the original fuse box through the new jumper. Power is fed through the original fuses and wiring to the lights .The new " power wiring" is all 12G
The original head light switch, dip switch and wiring to the fuse box are now used as a low power supply to trigger the relays.The relays feed 12volt power directly to the original fuses and wiring.
Max dog .

[cyberborikua]

Thank you Maxdog.

[spider2081]

Im planning on using the SAE connector type to marry them with the OEM ones. Easier and faster that way.

If you are talking about the 2 pin connector for the light buckets the SAE 2 pin connector and the single bullet connectors are a larger diameter than the connectors used by Fiat. The original male pin will be loose in a SAE female socket. I know folks simply squeeze the female to tighten it. It is simple and cost effective not sure how dependable it will be over time.

[cyberborikua]

Darn it. Those are bad news. Yes I was talking about the OEM ones made by Fiat. I know Auto Ricambi offers a harness kit with those connectors and even sell those SAE connectors individually.

[spider2081]

I did not purchase any from AR so I can't tell you theirs will or not fit correctly. I have tried a number of vendors and parts suppliers and so far have not been able to source the correct size 2 pin connector. The pin spacing is close enough but the diameter is very questionable. I even tried some European sources. I have positioned the relays on the drivers side fender well in such a way I cut off the cars 2 pin connector, install new spade connectors to the cars wires and connect them to the relays Then reuse the 2 pin connector to make the connection of the relays back to the driver side bucket. I also prefer not to use the prewired relay sockets.

[cyberborikua]

Done installing the relay. Ended up buying a kit ($17) and replacing the three prong connectors with 10-12 gauge single bullet ones to be inserted into the stock bullet connectors. I also used the stock grounds to the headlights and grounded the connector going to the switch. This way I did not have to cut the stock bullet connectors. All worked as expected, lots of brightness now! Total project time was 45 mins, including a trip to the hardware.

[spider2081]

Nice. Always good to hear when someone solves their issue. Where did you purchase the single bullet female connector to properly mate with the original Fiat male connector??? I have been trying to find a source for some time.

[cyberborikua]

I found them at Home Depot. A pack of 10 female/male for less than $3. There are different gauges. I used the 10-12 gauge and they fit perfectly.

[spider2081]

Thanks I'll check it out

[spider2081]

I was at Home Depot and remembered you saying you purchased the single bullet connectors there I couldn't remember which wire size you stated but in eyeballing the yellow 10-12 and the blue 12-14 it seemed like the bullet ends were the same size so I purchased the blue colored ones. I tried them on a spare headlight bucket 2 pin connector and yes you are correct they fit very well.

Thanks again for sharing this info. I had all but given up looking for a connector that fit tight with the Fiat 2 pin connectors and now I have a source right under my nose.

[bjbrown]

To those of you who have installed headlight relay upgrades, would you please show some photos of your installation and list the year of your car?

[RRoller123]

Not very fancy, but I mounted a relay, one each for the HI and LO beams, on the sidewall, intake side. Also had upgraded the ground pod a couple of years earlier, visible at right.

Probably not necessary, but I also put a small piece of dense foam rubber under each relay mount in an attempt to absorb some shock. So far so good after a few years.

[bjbrown]

I'm putting the headlight relay fix into my 1980 spider now. I have the Daniel Stern product solution with new H4 headlamps, relays, fuses (for power to the relays for the lights) and a connector to pull the signal from the original sealed beam connector. I plan to put the relays on the driver side of the engine compartment and draw power from the alternator post. I'll have two 20 amp fuses - one for high beam, the other for low. Question: How are you guys routing the new power wires over to the passenger side? I'm planning to use 12 AWG wire from the relays to the lights and the same gauge to ground. I'm thinking of running the new wires under the top radiator support with a sheath. Is there a better way?

[njspider]

I just installed the headlight relay kit today. Bought it from AR. I'm not real confident working with electrical issues but this was super easy and makes a huge difference. No cutting or splicing, just plug and play.