Just curious as to any problems anyone may have encountered after making this modification.

I measured just over 10 volts at the headlight plugs before adding the relays and just over 14 after the install.Without a doubt yes...the lights are a lot brighter but will the higher volts kill the lights in short order or possibly even melt the original wires between the lights and relay down?

I have ran about 7' of 10gauge wire straight off the alternator output stud around the engine compartment to a fusible distribution block with 20amp fuses,then on to the 40amp relays and then to lights.I also have added extra grounds for everything to hopefully avoid any problems.

I'm wondering now if I can just be super impressed at the drastic difference in light output or paranoid that at any given moment both my headlights are going to go boom.

I would say no . . . go on any of the lamp manufacturer's websites to view the specs for the bulbs. I am sure they have a range of 12-14 volts. 14 volts is pretty normal for a good electrical system in a running vehicle.

Good to hear you used circuit protection in the system. I would suggest changing to circuit breakers instead of fuses. That way, if there is an issue, the breaker will trip, but try to reset itself. With the fuse, once it operates, you will be dark with no lights. So, either keep spare fuses for the headlight system, or use a circuit breaker. Just my two cents worth . . .

Sit back and enjoy the light!!

Mark

Amp draw goes down as voltage goes up, so you should be just fine. With the large gauge wire there should be very little resistance. I did the relays in my plow truck and it definitely made a difference.

Guess I should clarify since after I read it,it looked a bit confusing.

The new 10gauge wire is from the back of the alternator to the new distribution block only.

From the 20 amp fused distribution block,I am using I think 12/14 gauge wire for main power to the relays.

Out of the relays to the headlights themselves is just the stock wiring.

Sounds like we may be good to go though,thanks.

Most factory headlight wiring is 16 gauge, so if you are 14 or 12 you are definitely upgraded. You should have zero problems.

Your wire size is fine . . . stock headlights draw 35watts. Which for amperage = 35watts/12volts = 3amps (approximately). Your wire size can handle a lot more than 3amps !! . . .

No worries . . .