Headlight's Done

Finished up this upgrade today, though I *may* need to revisit it at some point due to headlight bucket depth. The connector on the back of the headlight pushes up against the back of the bucket so if adjustment proves to be impacted, I will need to open up a hole in the back. Not something I want to do unless I have to.

The Painless harness has a connection to one of the original headlight plugs. I pulled the left one off the headlight and out of the bucket to connect up. Here you can see I have used Rescue Tape to waterproof the connection. I also used dielectric grease on the contacts.

 I used a step drill to enlarge the hole in the bucket so I don't need to pull the wires out of the socket to feed them through a small hole. 

Slipped a grommet onto the wire, then with the wire inserted, pushed the grommet into the hole. It's not going to stop rain water from being splashed into the bucket, I'm afraid. But all connections are either weatherproof or have dielectric grease or both.

The relays are mounted inside the fenderwell. They are completely weathertight so no worries about them getting wet. The fuse hangs loose in the middle to accommodate easy replacement with a fresh 30 amp one, if needed. I may adapt this to a breaker later on.

 I rewired the terminals from the alternator to fix the problem with the ammeter and this made the perfect place to wire in the headlight harness power and ground.

A touch of dielectric grease and the connector is ready to go on the new headlight.

First side done.The other side will be simple by comparison since all the heavy work of mounting relays and wiring the source is already done.

Trying to be discrete and non-destructive, I routed the harness for the right lamp through the bumper grommet and across the pan in front of the radiator. Of course it will be visible when the hood is open if you look down into the space in front of the radiator, but it is protected and unobtrusive. Also very removable if the next owner wants to make it original.