Ignition switch failure/ headlight relay kit

[ICTRocket]

the wireing diagram is almost perfect, you only run the negative to the relays the lights already have a suitable earth, earth is not the problem area, otherwise yep spot on
Yes 30amp 12 volt is perfec,t I run a 20amp large blade style (on the left in picture) fuse at the battery end so if you ever blow a fuse it is easy to get to I was nearly tempted to buy the relays that have piggyback fuse but then you would have to lift the tank if you blew one!
I used 25/30 amp dual core (inside an extra cover tubeing) for the power supply + & -- it's 4mm not sure of the conversion you will need about 3 foot but allow a bit extra when you buy it just to make sure, you need to cut a 6 inches of and slice it in 6inches in from the end
You will also need 3mm 15/20amp dual core from relay to harness you will need 3 pieces about 14 inches long
you also need shrink wrap tubing and some insulation tape also two eye type connecters to connect the wires to battery if you find your battery terminal bolts are two short buys some m6 stainless steel bolts another thing I use and should be available at you Auto spares shop is electrical grease use it on all connecters and where ever possible solder all joints it is even a good idea to put some solder on wires you are going to crimp and use a good crimper.
There I think I have covered everthing I will be making one of the harness up this weekend and take pictures for those who are not sure about what I mean about splicing the power wires

Hanso,
thanks for the knowledge! I looked up the wire conversion on the net. For us in the States, 4mm is 10 gauge wire, 3mm is 18 gauge.

Please do post pictures!

I think I can do this for $25 - $30.....far cheaper than the $75 from EB with the shipping.

 

[HansO]

Hanso,
thanks for the knowledge! I looked up the wire conversion on the net. For us in the States, 4mm is 10 gauge wire, 3mm is 18 gauge.

Please do post pictures!

I think I can do this for $25 - $30.....far cheaper than the $75 from EB with the shipping.

ven cheaper for Aussies... more shipping

Kiwi and CanberraR3 I have the bits for one and the couple of bits they did not have in stock for the other they will have next week, I'm for the purpose of pictures going to make one upthis weekend, a little longer than mine to allow for Kiwis std air intake (somthing we will have to talk to you about Kiwi (note to CanberraR we will work on him) and he won't regret it.

Oh did I tell you my headers arived this morning

 

[CanberraR3]

Yes, we'll work on Kiwi. Will give you a call to sort out best time to come down - hopefully together and hopefully accompanied.
Can't wait to see/hear those headers. Hope they won't make you want to go too fast or anything

 

[HellFire]

Oh did I tell you my headers arived this morning

I'm afraid to ask what those cost.

 

[HansO]

I'm afraid to ask what those cost.

Cheaper than I could get them made here in Aussieland and by the famous Merican man of "Prediter" fame Sam also known as "Lazarus" here on this forum

sorry not sure if Sam wants prices pubicied but I don't think he could be making any great if any profit his welding is of top quality he had them Cermic Coated and they are Stainless Steel and had enought packing to wrap a space shuttle

 

[HansO]

here are some picture showing the splicing of the power + and - wire for connection to the two relays

 

[HansO]

conecting the power wire to fuse holder, also a note to those that are inexperienced when crimping wires always put a bit of solder on wire before crimping and if you are useing nonisulated connecter like these tha clip into a back of the blocks heat and apply more solder after

 

[HansO]

as you can see the connecter blocks save a lot stuffing around and very easy to use but remember to use electrical safe grease esepecially if you live near the coast to stop corrsoin in your connections I have more pictures if any body want them, this the harness for Kiwi so if You are watching give me a call to organise a fitting I also have yours canberra R3 just waiting on the relays should be here tomorrow

 

[HansO]

just picked up the other parts and will put your's together now aswell CanberraR3 by the way cost $30 each for parts labour for free just let me know when you two want to come or down or I can come up the mountain, I'm easy... not in that kind of way thou!!!

 

[CanberraR3]

Fantastic. Any time suit you next week? Or this w'end (so Amanda can come too)???? I know you work odd hours so will fit in with you. Sorry couldn't talk today - will call you tomorrow (same time?). Mal, if you're watching, would be good to get down there together.