HD Headlamp Harness DIY

[Greenie]

The subject of improving headlamp performance of the Tundra has been discussed many times on this forum. So after perusing the plethora of threads on remedies I concluded that building my own heavy duty headlamp harness suited my individual needs. See my post from "What headlight bulbs are yall running?" thread below.

The results are dramatically improved headlamp performance and enhanced night seeing. Overdriving my headlamps is NOT a concern anymore.

I am now using Osram 70/65W Super Bright BILUX H4 Off-Road but only after fabricating a new custom heavy duty harness with relays. The heavier 14 gauge wire allows the bulbs to utilize full voltage as opposed to the voltage restrictive stock headlamp wires. An added plus is that the ceramic headlamp sockets supplied with the kit along with the heavier wiring addresses the danger of overheated stock headlamp wiring when using higher wattage bulbs.

The kit was ordered from Daniel Stern with the exception of the wire (which I bought locally) and they are top quality parts. No Chinese bric a brac here.

I made up my own wiring diagram before starting the project to be able to double check my work as I made up the harness in sub-assemblies.

No cutting of stock wires. All custom components plug in to stock wiring maintaining the stock headlamp dimmer/headlamp on off switch as the switching device. Easy enough to return to stock configuration if so desired.

An additional note: Headlamp lenses should be in as new condition, if not then headlamp performance will be compromised. Clean them up with your favorite headlamp restoration kit to benefit from the wiring and bulb upgrades.

The higher wattage bulbs combined with the new heavier wiring brings the stock Tundra lights into the high performance category. Before the upgrade high and low beam lighting was substandard to say the least. Now on high beam the distance at which I can see approaching signs, Botts dots, reflective construction barrels and so on is more than double what it was with the stock setup. And low beam is equally improved.

I can't speak to Mr. Stern's low esteem for HIDs but he does know lighting technology. I think he regards HIDs as more of an expensive gimmick than a practical and cost effective solution for existing inadequate lighting performance.

I am certainly not qualified to make any quantitative comparisons of HID lighting versus conventional lighting technology. However I did not have to modify my headlamp housings as is often the case with HID conversions. For my specific application HIDs were not a viable option.

I can say that his suggested course of action for my particular lighting needs was spot on and performed as advertised.

[adamjt]

Can you post the link and model of the kit you ordered? I'm interested in doing this. Ever since I had a car with HID's, I can't get used to how bad my 2001 Tundra's lights are.

[hilandfrog]

First off Daniel stern is top notch good stuff and ideas on their site.

actually getting full power to any bulb will help, but the upgrades you talked about seem to be the most important and yet most overlooked.

I'd have loved a ceramic socket a few years ago for the jeep.


Repo

[Greenie]

See link below for kit information.
Daniel Stern Lighting Consultancy and Supply

Relay kit: RIK-2T ($59)
Osram 70/65w +50 H4 bulbs: $22 ea. X 2
Shipping: $9.98
These were the prices as of 5 months ago.

He accepts Visa and Mastercard.

I recommend a personal one on one consultation.
Contact him at: tech@danielsternlighting.com or dastern@torque.net

Unlike some online vendors he is reputable, knowlegeable and will do his best to explain any questions you may have no matter how elementary.

I highly recommend Mr. Stern as he knows lighting technology and is the go to authority on lighting upgrades, kits, bulbs, auxiliary lighting and solutions to inadequate automotive lighting.

Good luck with your project.

[bamafire]

Sounds neat Greenie. I'd like to see them sometime, as well as your sunroof (which I'm jealous of and considering) . I work at the VH fire station on Columbiana Road. I may try to twist your arm to come by one day to show me this stuff if you're bored.

[RCJAY]

When everything is said and done. Are they as good as HIDs.....??? Any pics on a tundra can be posted??? Thx

[Greenie]

When everything is said and done. Are they as good as HIDs.....??? Any pics on a tundra can be posted??? Thx

You will have to consult someone more knowledgeable than I on the question of which is actually best, an upgraded conventional system or a HID conversion. I'm sure empirical data exists that would either corroborate of refute one claim over the other. Common sense tells me that HIDs are better as original equipment over a conversion. Since not everyone has perfect vision this is a subjective question anyway from a lay person's point of view.

Current thinking favors the light output and longevity of the HID system (up to 3 times longer than a Halogen bulb) although an upgraded conventional system will most likely provide enhanced lighting needs for the average motorist. Those who must stay ahead of the curve will not be satisfied with halogen systems no matter how good and thus the current flood of after market HID kits to satisfy this market. Keep in mind also the high voltage aspect of HID starting (25,000 volts) but only 80 to 90 volts to operate once the arc is formed and high operating temperature of the ballasts.

Most automotive pundits agree that original equipment HIDs outperform Halogen. Light from a HID xenon bulb is 4100 degrees Kelvin. Light from a standard Halogen bulb is 3200 degrees Kelvin so judge for yourself.

Personally I don't think it's worth the effort to modify existing headlamps to accommodate a HID retrofit. The reason being that the existing lens and reflector are engineered specifically for a Halogen filament bulb to exacting tolerances. Close examination of your headlamps reveal a complex facet array in the reflector to produce the desired beam patterns. Retrofitting a HID bulb in this headlamp negates the Halogen beam pattern manifesting in glare in some areas and insufficient light in others. In other words the retrofit will be brighter but not as efficient as before.

A retrofit headlamp assembly with reflector re-designed to maximize the light output of a HID xenon bulb and constructed to take the heat might be a viable alternative if money is no object. Cost to benefit then becomes the deciding factor.

Pictures would be of little value given the variables of type of camera, lens, weather, ambient light, etc. and lack of scientific equipment to quantify results. If you want scientific data it's not here. I can report that from my personal observations there was a remarkable improvement in performance. You are free to make your own decision as to whether this project is worth your effort or has validity.

When dealing with automotive lighting many subscribe to Mores Law. That is if more is good then too much is just right.

[RCJAY]

Wow that was alot of info thx. I was asking for photos of your install in your tundra not the look of the light. Of course through a camera can't really tell how bright it really is. Did your install take long bTW??? And about what % is it brighter then our stock lighting system in your option?

[Greenie]

Wow that was alot of info thx. I was asking for photos of your install in your tundra not the look of the light. Of course through a camera can't really tell how bright it really is. Did your install take long bTW??? And about what % is it brighter then our stock lighting system in your option?

If you download the pdf you'll find photos of the install.

The install only took about an hour however the actual assembly of the harness took place over a couple of days working a few hours at a time. The point being that it's not a good idea to rush through such a complex project.

If you read the initial explanatory DIY thread below there is commentary on the efficacy of the improvements.

Quote:
Originally Posted by Greenie

The higher wattage bulbs combined with the new heavier wiring brings the stock Tundra lights into the high performance category. Before the upgrade high and low beam lighting was substandard to say the least. Now on high beam the distance at which I can see approaching signs, Botts dots, reflective construction barrels and so on is more than double what it was with the stock setup. And low beam is equally improved.

[RCJAY]

If you download the pdf you'll find photos of the install.

The install only took about an hour however the actual assembly of the harness took place over a couple of days working a few hours at a time. The point being that it's not a good idea to rush through such a complex project.

If you read the initial explanatory DIY thread below there is commentary on the efficacy of the improvements.

Quote:
Originally Posted by Greenie

The higher wattage bulbs combined with the new heavier wiring brings the stock Tundra lights into the high performance category. Before the upgrade high and low beam lighting was substandard to say the least. Now on high beam the distance at which I can see approaching signs, Botts dots, reflective construction barrels and so on is more than double what it was with the stock setup. And low beam is equally improved.

Thanks so much , I did download the pdf file and been looking at it. Do you happen to have to link to your orginial post of this DIY project.

[PagalDesi4Life]

Greenie, can you reupload the pdf file, it doesn't seem to load right now.

[Mr. Creosote]

There is a problem with the server in this regard. Please stand by.

[Greenie]

There is a problem with the server in this regard. Please stand by.

Wow! I'll say there is. I posted this link in a different thread yesterday as an FYI for a new member. Uploaded files are also problematic.

[PagalDesi4Life]

Greenie, since you are using a heavy duty headlight harness and a higher wattage bulb, have you noticed that your headlamps are warmer then compared to when you had the stock bulbs in? Of course this is attributed to the higher watt bulb but I was wondering if the extra warmth of the headlamp was a concern to you or not? I purchased the hd headlight harness from suvlights.com last year, ran it with stock bulbs, didn't notice a difference in light output. However it def worked fine with a higher watt bulb but the headlamp was insanely warm (can def fry an egg over it) and so I wonder if warmer headlamps were of a concern to anyone or have been an issue to anyone.

[Greenie]

Greenie, since you are using a heavy duty headlight harness and a higher wattage bulb, have you noticed that your headlamps are warmer then compared to when you had the stock bulbs in?

I have not noticed any appreciable increase in the surface temperature of the headlamps since installing my new headlamp harness. However, my bulbs are Osram 65/70 watt and are not significantly higher wattage than the stock bulbs but are considerably brighter.

Of course this is attributed to the higher watt bulb but I was wondering if the extra warmth of the headlamp was a concern to you or not? I purchased the hd headlight harness from suvlights.com last year, ran it with stock bulbs, didn't notice a difference in light output. However it def worked fine with a higher watt bulb but the headlamp was insanely warm (can def fry an egg over it) and so I wonder if warmer headlamps were of a concern to anyone or have been an issue to anyone.

The other variable in the equation is the harness. I have not personally examined a harness from suvlights so I cannot comment on the wire gauge, relay(s) or whether they use ceramic sockets for the bulb connection or the quality of components.

"The second law of thermodynamics states that heat does not of itself pass from a cooler to a hotter body. Another, equivalent, formulation of the second law is that the entropy of a closed system can only increase." Simply put, a heat source (an excessively high wattage incandescent bulb) could overcome the ability of the surrounding structure (headlamp housing) to dissipate the heat.

Increased heat with increased wattage is an inescapable consequence with incandescent bulbs. You did not mention what wattage or brand of bulbs you are using but if your high beams are 100 watts or more and the low beams are either 80 or 90 watts then you'll have significant heat generation. My personal preference would be not to exceed 80 watts on high beam. Is this "extra warmth" from high beam or low beam?

If your headlamps are as hot as you describe then there is the risk of the lens/reflector sustaining damage not to mention the lens to reflector bond being compromised. This should be a not so subtle hint that either your bulbs are too "hot" or the harness is not doing it's job or a combination of the two.

Check your wiring while the lights are in operation. If the headlamp harness in the immediate proximity to the headlamp boot is hot while the headlamps are in operation then the harness is not up to the task of the higher wattage bulbs.