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  • Headlight Relay Kit

    Studying my TR6 and looking at where I can get the 12v power for a headlight relay system. My guess is with 2 x 60w headlights, that would be 5 amps each at 12v, or 10 amps total.

    Can I "steal" the power from the brown side of the fuse box? Is 10 amps too much to draw there?

    Or should I find some way to get power directly from the positive terminal of the battery (I can't seem to find any "add ons" that will give me the ability to wire up a power wire there).

    Anyway, I know many 6-Packers have done the conversion, so how did you guys get the 12v power for the relay assembly?

    Thanks.
    1976 TR-6 BRG - CF57239U
    Carbs by Poolboy
    Rear Camber Kit, Rear Hubs by Goodparts
    Gear Reduction Starter by TSI
    Distributor by British Vacuum

  • #2
    I took it off off the back of the alternator, taped it to the harness so you cant see it then put it through 2 self resetting breakers, one for each headlight. Mounted the relays and breakers up front by the overflow bottle on a flat 2" x 2" piece of black ABS plastic then mounted it to the inner fender using an existing bolt. It's easy from there to take the old power to the headlights to activate the relays for dip and high beam.
    72 Pimento w/overdrive

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    • #3
      I made my own kit out of two Bosch relays and sockets I had lying around. I used the high and low beam wires running to the headlights to trip the relays, and I used an heavy inline-fused wire directly from the positive terminal of the battery to power the headlights. (fuse it as close to the battery as possible).
      SR
      73 TR6. HT/AC/OD
      86 930
      91 535i

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      • #4
        Hi Bart
        We can get together and you can take a look at my install. I'd stop by this week but the is going in for some minor work tomorrow.

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        • #5
          You could take the power from the battery.
          that way it would not stress any other components.

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          • #6
            I would prefer that approach, Ivan, but wanted to know what hardware was available to "camp on" the battery terminal. I'll call about looking at your car. Thanks.
            1976 TR-6 BRG - CF57239U
            Carbs by Poolboy
            Rear Camber Kit, Rear Hubs by Goodparts
            Gear Reduction Starter by TSI
            Distributor by British Vacuum

            Comment


            • #7
              There's a lug on the back of the alternator. It's the same as going the battery and it may require less of a wire run to the relay which is a plus.
              Lou is an Electrical Engineer and since he said he did it like that, that was good enough for me to follow in his footsteps.
              Here's my set up...the brown wire is going to the alternator.
              Driving a 1973 TR6
              Doing ZS carb repairs
              email kencorsaw"at"aol.com

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              • #8
                Originally posted by bartman View Post
                I would prefer that approach, Ivan, but wanted to know what hardware was available to "camp on" the battery terminal. I'll call about looking at your car. Thanks.
                I used a "ring" style terminal connector. I soldered it to the end of the wire. I ran the battery clamp bolt through the ring and bolted it directly to the battery clamp.
                https://www.delcity.net/store/Non!In...23560.h_806204
                Link to what I used. Available Home Depot/Lowes ACE...etc.

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                • #9
                  Thanks, Lou, Ivan and Ken. Those both look like possibilities - I'll study it more and determine where I want to mount the relays and circuit breakers. I like the idea of the circuit breakers because it removes yet another unfused circuit in the car. Bussman offers breakers in manual reset, automatic reset, and modified automatic reset. They fit into an AGP fuse panel (although a bit taller).

                  Click image for larger version

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                  1976 TR-6 BRG - CF57239U
                  Carbs by Poolboy
                  Rear Camber Kit, Rear Hubs by Goodparts
                  Gear Reduction Starter by TSI
                  Distributor by British Vacuum

                  Comment


                  • #10
                    This is the kind I used since I was trying to avoid the having to stop and reset it at night on the side of the road bit. I searched for the size/model I wanted and got them I think from Amazon with free prime shipping for a few bucks.

                    https://www.delcity.net/store/12V-Au...SABEgJxQ_D_BwE

                    I mounted them on flat piece of plastic like Ken, you can see one in Ken's picture. My whole relay/breaker "board" is mounted up by the headlight on the inner fender. I used bullets to connect it in so that it could be removed back to stock if a future owner was so inclined.
                    72 Pimento w/overdrive

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                    • #11
                      Hey Bartman,
                      I've got the TR back home and in the garage....let me know if you want photos or can stop by.

                      Enjoy.

                      ibjean325

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                      • #12
                        Thanks, Ivan. I'll call. If the weather is not too brutal tomorrow, will you be home?
                        1976 TR-6 BRG - CF57239U
                        Carbs by Poolboy
                        Rear Camber Kit, Rear Hubs by Goodparts
                        Gear Reduction Starter by TSI
                        Distributor by British Vacuum

                        Comment


                        • #13
                          Originally posted by bartman View Post
                          Thanks, Ivan. I'll call. If the weather is not too brutal tomorrow, will you be home?
                          Sure. I should be home most of the day. Call me. If the weather holds - I can stop by to your place..

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                          • #14
                            I built my own relay system - ran the power from the starter post, which is effectively from the battery
                            Dave C
                            '72 Sapphire #CC82360UO
                            Chapel Hill NC

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