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G'day I'm Brett.
Now a common problem with early Defenders is
the headlight switch burns out due to the lack of a relay.
The high currents cause the inside contacts to melt and you lose your headlights.
So I'm going to fix that by adding in a simple relay in to my headlight system.
Here's how.
You'll require the following things:
Soldiering iron
Crimping tools
H4 female connectors
H4 male connectors
inline fuse holders
relays and block
assorted electrical cables
heat shrink
and split tubing.
Start by crimping your battery connector and then solder into place.
Run your cable from your battery box to determine the correct length.
Cut as required
and start crimping and soldering all the connections for the block.
Insert all connectors until they click in to place.
This male connector plugs in to your existing headlight loom and controls the relays.
This plug connects in to your headlights.
Once all connections are completed run split tubing along all wires to protect them.
I've included 2 fuse holders to protect my low and high beam circuits.
The left connector plugs in to your headlights and the right in to your existing loom.
I'll let the results speak for themselves.
This is my original headlight switch showing the melted contacts.
The total cost worked out around 130 Australian Dollars.
Parts were purchased from Ebay and my local auto parts supplier.
Google headlight relay to find a suitable wiring diagram to follow.