Technical H4 (halogen) headlight conversion

[Bleeding Knuckles]

When I fitted the same system in my car I had no concern for amps, watts or volts, DC or AC. But I did understand the principle of what I was doing. The key things for me were to have reasonably heavy-gauge wiring, safe cable-routing, appropriate fuse arrangements and secure terminations. This was all made easier by a clever little mini-loom that cost peanuts off eBay.

MAL_1115 by Peter Thompson, on Flickr

The mathematics of the lights/relay setup are good to know (when you understand them) to confirm that it's all going to work safely. But the maths have already been done as evidenced by the vast numbers of cars safely running with halogens.
A month or so ago I drove a continuous 120 miles in the dark using the halogens and my additional spotlights when possible; that was nearly three and a half hours of a lot of amps and the car lived for me to tell the tale.

PS. One of the photos may be faked in some respects.

thefinalsolution by Peter Thompson, on Flickr

Blimey Peter, if you used that layout opposing traffic would see you mmmmmiles away and then you could burn out their retinas as they pass
Ian.

 

[Nowuries]

Aha! I thought it was a 500-specific item, but it makes sense that it is a general wiring harness. Thanks so much for your time and help!