Okay, it has been made painfully obvious my 66 is not designed to take 100W Xenon bulbs. Replacing the headlight switch only hid the problem for a year before rearing its head while I'm going down the road at night...upon the warming up of my switch, my headlights will start flashing on and off. The new wiring harness under the hood removed doubts of faulty wiring, all grounds are good(and new), but the switch is the weak link. After installing the lights I realized that the book suggested hooking a relay from the battery to the light switch in order to keep the switch from burning out. So my questions are as follows: Has anyone here done this before? If so, how do I need to go about installing one, and what parts will I need to do so?

Oh yeah, one more thing, is there a voltage regulator that will withstand 100AMPS, mount into the stock wiring harness, with an original designed alternator(rebuilt, gives off 100Amps, but has the old style wiring)?

Thanks in advance for any help.

 

Can anyone out there help me with this?

 

i know there is a kit that takes power from the battery and goes straight to the headlights. it has a relay and your headlight switch is just that, a switch. right now the power goes thru your switch. ive seen the kit in my 73-87 chevy truck catalogs, but you should be able to find them elsewhere. maybe try summit or jegs, painless wiring might make it. if you cant find it, then try a 73-87 chevy parts house. the kit will work with both vehicles as long as your 100w bulbs are the H4 style. i imagine they are?

 

The relay thing is proably a better idea but the old falcons had 4 headlites and the circut breaker was stronger its a direct replacement.

 

Yes, you can get a 100 amp alternator. If fact, that is a good idea if you are running any whoopty doo stereo equipment. But, You will absolutely have to change the size of the wiring. According to USCG wiring chart a 100 Amp circuit with a conductor length of 10 feet (5 feet on the + side and 5 feet on the negative side) you would need 4 gauge wire. For 15 or 20 feet you need 2 gauge and for 25 feet you need 1 gauge wire.

 

someone posted a website on here about brighter headlights. If no one posts it today, i will get if for you and post it on here. It's on my other computer. It showed how to wire up relays. It's cheap, and not difficult.

 

I have had the 100amp alternator installed(has been for a year), the battery cables AND ground cables are already much larger than stock(as well as a few others). I have a radio, it is the original AM radio, still works, but I removed the speaker. The sequential tail-lights, xenon headlights, and electric fan are the only major drains on the electrical system.

Silver Ponys, that is a good idea, the 4-light breaker might work, but I still may try the relay.

Thanks for the help everyone.

 

here's that relay link

 

Is there a place that I can buy one already assembled?

 

Yeah, i think that website said there was, but why would you buy that?? It'd be cheaper to just do it your self. all you need is basically two relays and alittle electrical knowledge. I can sorta talk you through it.... but that website tells you all you need to know really.