deconstructing the morimoto HD relay.

[saucebox]

not to beat a dead horse, but..

The change in operation with proper wire, relays and terminals is outstanding.

I don't know why I didn't get real stuff sooner.
The main breakdown points are the terminals in the 9006 connectors to the ballast inputs, and the relays. To some extend the wiring isn't great but passable. mori.
I wouldn't order or use any ebay, amazon or regular hid online supplier stuff for wiring. The headaches are real. I also know the makers chase the lowest price as does the everyday user so I get it.
A set it and forget it single relay set with proper everything will cost about 75$ and last for a very long time.


ballast failure buzzzing whining, spark black connector HID wiring GXL TXL 9006 9005 HD relay hidplanet morimoto loud relay delayed ignition hid problems defective ballast

If that second one ever made it into production...I'd be happy to take it off your hands. Doesn't seem too difficult to make, but I just don't have time now that school is back in session. The output is so good that I've put up with the BS for going on 2 years now. Replacing ballasts and even the harness (not knowing about warranty ) just patches the problem for a short time.

 

[jerryb]

I was thinking about having those guys make them and sell them, just get a normal spec consensus. But really if you just tell them on the phone they will make it for you.
Other thing was the mounting place that people like. I have mine next to the daytime running light relay on the next ground bolt on the fender.
Length of all the legs matters.
and what people like for wire. 12,14, 16 gauge, 10 is overkill in my mind. The mori relay set is too long all around.
I'm a little lost on it really. I'd make them no problem and so would that guy at that company.

then there's the , where are people mounting their ballasts? I could get all the parts but really it's just easier to order from them.
I don't know how long I'll be at home.

this is what I would do if I needed another one.

1 hella 40 amp W/P with socket.
Socket with gxl/txl 14 gauge 50" long on all but the pin #30 and put 12 gauge on that one 50" long (GXL)

get an inline fuse holder 15amp, 12 gauge with ring terminal on the end for m8 stud hole.

one ring terminal for the ground lug on an m6 stud, same stud as the relay mounting hole, pass fender side by air box and daytime running light relay.

one male 9006 connector with terminals and seals.
two female 9006 with terminals and seals.

figure 80$ plus 10 for sending that along. Probably more from that company considering they spend time crimping and making them.
If/when I come home in december I might order a bunch of extra headlight terminals and connectors and some wire gauge I don't have at the moment.
idk.

 

[Gnarwgn]

Just to close off my brief rabbit trail...warranty replacement harness arrived. The o ring/wiring connection point (wrapped in red and black tape) seems to be alot sturdier than the previous failed version. Switched it all out and fired up just fine, as I expected. Now for the test of time...

 

[jerryb]

It appears I'm going to make these an offer them.

As a single relay for 35w ballasts. Double if wanted.

I have been running with double, power and ground combined, on a 15 amp fuse without issue. ONe difference is I'm using real terminals.

I decided on 12 awg gxl pin 30 and 14 awg 87, 85 & 86. Longest leg is the battery, including 12" on the inline fuse total length is going to end up being 51" +or-. maybe length as wanted or a solder bullet included with an open end, or just bare wire to solder for custom length, or soldered and shrinked, Haven't really decided.

hella 40 amp NO weatherproof with mating socket. metal holder lug drilled out to fit the pass fender ground lugs @ M6 hole size with ballast grounds married and meant to terminate on the same lug as the relay holder.
passenger ballast input from relay 15"? or as wanted. drivers side ballast input from relay 48"? or as wanted.

little fuse inline holder.

Te connectivity ring terminals M8 power and ground lug. Battery stud, or studs on the stock clamp are M8. The ground lugs on the passenger fender are m6, the Te ring terminal is 8.4mm wide.

delphi/aptiv 9006 male and two delphi/aptiv 9006 female. see headlight connector thread here 9006 connector info
I'll probably make a different thread when I have one made. I don't know when.


relay harnesses available PM for info. relay sets.