Reason I don't.
I am OK with the headlight harness upgrade and the Wagner BriteLite versions of the factory headlights.

Were your relays mounted so moisture couldn't flow into them?

Probably not.
This was most likely my fault.
They were shoved into that square hole on the passenger side fender.
Kind of their back.

That will do it. And bouncing around isn't good either.

Yeah I know. LOL.
Kind of tight over there with the cruise and my fog light relay.
One of the reasons I want to move everything.
Plus seeing 1 more relay in my future and possibly a second.
Why I want to make my own headlight harness.
Just if the increase in wire length is going to diminish the effectiveness of the harness
then no sense in doing it.

The direction should not make a big difference. (Though I would never mount a relay upside down!) They should be sealed. But crap relays seem to be the only kind available these days. Bosch used to be good, but they have gone down the tubes.


I'm pretty sure they would smoke in a few minutes if you put 80 amps through them.


I have found that a lot of people use "Bosch" like Kleenex, just a generic name for a standard 5 pin relay.

No way you need 80 amps. That's just stupid. I agree with the above - 30 is plenty. 20 is probably fine.


Nah. That will help the connections, but moisture getting in is all about the quality of the relay. Or the lack of quality!

I really don't know if it's even possible to find a quality relay these days. Maybe in the marine world.....

Starting to realize that people are using Bosch as a generic name.

I still wonder why the relay from jhc7399, the one on Ebay, and the Ksuspension one (which all look similar) say 80A on them.
But yeah cause poking around the Putco that you see on Amazon uses 30 amp in both positions.
And this one here says 30/40A.

https://www.online-led-store.com/h4-...-accepscbl0201

And could somebody explain to me the 30/40A?
I mean either they are 30 amp or 40 amp right?
I don't get that.

I did find these:

https://www.waytekwire.com/item/7561...nector-75612-/

Then this but unsure if it is the right relay on the schematics.

https://www.waytekwire.com/item/7560...d-Mini-Relay-/

Also wondering about the terminals they sell. Can they be used with 10 gauge wire.
Which is probably overkill but considering that I want to make the harness longer thinking the bigger wire would be better.
And then I figure out a way to uses those connectors with the relays I use for lights which is a different schematic and not weatherproof.
Or find one that is.
At the moment I use these for my fog lights.

https://www.napaonline.com/en/p/LIT1...wordInput=192d

My problem is I don't have a clue.

If you want to do a clean job, you might consider something like this:


There are any number of these out there in assorted sizes. They are weather protected. Some are available from from marine suppliers like Blue Sea also. Most XJs have room on the right side of the firewall for this. My compressor for my lockers sits there so it doesn't work for me.

Seen them and it is a possibility.
Just a matter of figuring out where everything will end up.
This is the one that caught my eye.

that one seems a little large for the space that I'm thinking of, but whatever works for you.

Might be but I have not decided where I want it yet either.
It was more the combining the relays and fuses in one central location that caught my eye.
As far as the waterproof part goes the reviews say it is not really.

This one claims to be waterproof and the reviews don't contradict it.


Any protection is better than no protection and the end installation will be much neater. For 20 bucks, it seems like a deal as well as turning into a project.

Continuous 30, intermittent 40.

OK.
I would be lying if I did not say that was confusing the hell out of me.
Oh by the way I did find a 40 amp one where the schematics match locally too.

https://www.pepboys.com/novita-spdt-...roduct/1584213

https://www.autozone.com/electrical-...lay/849395_0_0

Same one just different pricing.

I don't get the need for a 40 amp relay for headlights. A 30 amp relay can supply 360 watts of power. Really high powered headlight high beams are about 100 watts each which results in a 200 watt load and a draw of about 16 amps. So the 30 amp would leave a lot of headroom for startup surge.

I am pretending that the voltage is 12 volts even though it will be in the 13-14 range with the engine running. The amps would be slightly lower under these conditions.