Headlight wires

[Guardm16]

Please give me a rundown of the headlight wires. One part of the manual says to discard the short wire extension cable, then the picture shows the extension. I was just going to run all the wires into the bucket and connect there but there is no way to fit all the wires through the bolt. I want to run the DRL, but I cant even get all the harness wires in. What is the trick?

The manual mentions: extra harness wires. What extra harness wires? also "Cut the 4’ blue wire in half." What blue wire is that? Are this in the RF box?

Thanks. Steve

[Dgc333]

I drilled out the hole in the mounting bolt. Can't recall the size but I referenced McMaster Carr for the same size hollow bolt and drilled to there advertised size. I also didn't try to run the ground wire into the bucket. I drilled out one of the rivets in the bucket and attached the ground wire from the bulb under a stainless button head screw. The ground from the harness I connected under the bucket mounting bolt against the grill mounting bracket.

[mkassab]

Steve, I also received your PM.

Here's my headlight post: https://thefactoryfiveforum.com/showthread.php?44055-Mark-s-35-Truck-Build-Extended-w-Gen-3-Coyote&p=550177&viewfull=1#post550177

I don't recall drilling out anything.

Good luck,
Mark

[DonImbimbo]

Steve,

No extra wires required for DRL operation and you can still have parking lights. I added two diodes right at the headlight switch wiring. Also I did not change the bolt but I did switch the harness over to heat shrink tubing.

216445

Don

[VIRGIN MIKE]

the LED lights draw much less current than incandescent bulbs (that the harness was designed to accommodate) so you can use lighter gage wires that will pass through the mounting bolt. I don't recall (from 4 years ago) what size went down to but I researched the current draw for the lamps and used the reccomended wire size for that amperage

[VIRGIN MIKE]

downsize the wires to the same size as the wires on the headlight harness; solid state bulbs use less current than incandescent bulbs so a short run of smaller wires is working for me.

[Guardm16]

I ended up grounding the harness on the inside of the radiator mount, and grounding the headlight on the inside of the bucket. This saved one wire (ground) not going through the center of the bolt.