New headlight wire mod for all X19's...

Well, here it is folks...
An INSERTABLE Headlight mod for your X1/9. I finally took the time
to put this all together in a nice neat package. There are no requirements
to cut ANY wires!! Keep your existing wire harness unscathed!

This mod fits BETWEEN your existing headlight sockets and
your new power-sucking super high output dual beam headlights.

Here is what the finished assemblies will look like"


border="0" alt="Image Hosted by ImageShack.us" />

What you will need to make your own:

(2) New H4 Dual Beam Headlight sockets. (get high temp ones!)
(4) 30 Amp BOSCH Relays. (Standard very popular relay)
(4) Relay Sockets (or 2 Dual sockets as shown)
(1) 30 Amp Fuse with holder
(2) "cheapie" H4 Dual Beam Sockets
(6) 3AG-style fuse taps (These will be flattened down & used with the cheapie sockets)
(2) Standard Spade terminals (Same ones used to attach to the X1/9's ground terminals)
(2) "Quick Disconnect" terminals (Get something good for 30Amps)
(25Ft) 10Ga. Red Wire (This will run from the battery or Main Fuse Block)

Misc: (optional)
Heat Shrink tubing
A Handful of "union" connectors (Crimp style) if you don't want to solder wires.



Equipment:
Hand Tools and a soldering iron.

Creating 1 Assembly:

The first thing you'll need is to create a "plug" to plug your headlight socket
into. Refer to the following diagram. Remove the wires (DO NOT CUT) from the
cheapie sockets. Flatten down all 6 of the 3AG-style fuse taps and insert them
HALF WAY into the connector as shown. Make them straight and solder into place.
Re-insert them back into the connector when done, making a "plug".



Hooking it to the relays:
Take one of the finished "plugs", hold it so you are facing the wires coming
out of the back of the plug. Position it so the top wire is Horizontal (-) and
the other 2 wires are vertical. | |

The Leftmost Wire will go to Pin 86 of Relay A.
The Top Wire will go to Pin 86 of Relay B.
The Rightmost Wire will go to Pin 85 of Relay A and Relay B

Connect a 12 inch long, 10-Gauge Red Wire to Pin 30 of each Relay.
Tie the other end of the red wires together with a quick-disconnect crimp.

Connect the new H4 Dual Beam Headlight socket's HIGH Beam side to Relay A
Connect the new H4 Dual Beam Headlight socket's LOW Beam side to Relay B
Connect the new H4 Dual Beam Headlight socket's GROUND to the Headlight pod's
ground connection using a crimp-on Spade terminal.

Lastly, run a 10-Gauge Red wire from the battery to a 30A Fuse holder, then to
the first headlight. Using the "other side" of the quick-disconnect terminal
used on the relay assembly, (pin 30, remember?) connect this wire to the
12" red wires that were installed on the relays. It might be a good idea
to run the 10Ga wire to the second headlight while you're at it....

All's left now is to mount the relays. If you don't want to drill new
holes, you can use 2-sided foam tape or get a 1" wide x 3.5" long x 1/8" thick
piece of brass or aluminum, (see my illustrations) mount the relays to one side
and drill a clearance hole to the other side and mount under the Ground Star.
(Located in the headlight pod area) Be sure to use star washers to maintain a
good ground!



Now follow this same procedure (above) for the #2 headlight, plug in a 30A fuse
and your done.

Included is a full schematic and a few illustrations. Good luck! Any questions,
just ask! -Bob