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Re: '58 Apache headlight relay install....
#98537 Wed Dec 20 2006 04:47 AM
Joined: Oct 2006
Posts: 125
cjoe Offline OP
There is alot I dont know or never will about electicity, how is works and why, but I can attest to what I see and what I read on a voltmeter and the lights are now brighter and now operating on approx. 1.5 volts more than before the relay installation. I used the alternator as my bus because it is very close to the headlights and gave me the shortest wire run possible with no voltage loss. Breaker and relays are mounted on the inner fender close to the horn, again very short wire run to the headlights. Short heavy wires means less voltage loss. Alan said probably old wires, less than perfect connections, and long (maybe undersized..??) wire runs caused the early lower voltage reading (before relay install). I agree completely with his diagnosis and thank him for sending me the website with the install information. Thanks Alan

'58 3600 350/4-sp/stepside/big window cab
'59 3100 235/4-sp/stepside
Re: '58 Apache headlight relay install....
#98538 Wed Dec 20 2006 04:50 AM
Joined: May 2003
Posts: 1,274
Shop Shark
I'm more than happy to have been a help, Brother!

Alan Horvath
54 Chevy Pickup
Re: '58 Apache headlight relay install....
cjoe #1128825 Sat Oct 10 2015 03:11 PM
Joined: Feb 2008
Posts: 78
Shop Shark
Carl - Can you send me details as to how you hooked the wiring harness head light points into the relays? I am lost after the point of running the 10ga wire to the breaker then to the relays. I can do this with no problem. Not sure how to connect the harness portion to the relay(s. At what point do I make the connection and to what contact on a specific relay?
The system sounds simple and working great, have 2 trucks that need it due to flickering high beams.

1958 Chevrolet 3600 NAPCO 4x4 Apache
In the Stovebolt Gallery
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Re: '58 Apache headlight relay install....
58NAPCO3600 #1331362 Sun Oct 27 2019 02:17 AM
Joined: Feb 2008
Posts: 78
Shop Shark
After a considerable time off of working on the truck, I am back on it now. I just found and connected a hi tone horn. This is much better than a single low tone horn. Found some spectacular headlights, components and schematic thru Daniel Stern Lighting. Looking forward to being able to see at night. I will post pictures of before and after when finished.

1958 Chevrolet 3600 NAPCO 4x4 Apache
In the Stovebolt Gallery
More pictures on Photobucket
Re: '58 Apache headlight relay install....
cjoe #1331384 Sun Oct 27 2019 01:57 PM
Joined: Feb 2004
Posts: 20,568
"Nothing new under the sun", as an Old Testament prophet once said. Back in the 1940's and 50's using a headlight relay on 6V lights made the lights bright enough that oncoming drivers would flash their lights, thinking the relay equipped car was running high beams. It's all a matter of reducing voltage drop every time current flows through another switch, conductor, or connector.

The murder victim was drowned in a bathtub full of Rice Krispies and milk.
The coroner blamed the crime on a cereal killer!

Cringe and wail in fear, Eloi- - - - -we Morlocks are on the hunt!
Re: '58 Apache headlight relay install....
cjoe #1331910 Wed Oct 30 2019 03:02 PM
Joined: Dec 2017
Posts: 769
Shop Shark
Its a worthwhile project for certain. I did it and it was a tremendous help in seeing at night (I also moved up to H-4 Halogens).

So take a look at the factory wiring diagram and find where the hi and lo wires for the headlight switch run in the engine compartment along the inner fenderwell. Then look to see where the wires bifurcate to feed the left and right bulbs (usually pretty close to the radiator saddle and voltage regulator.) Unwrap the wires and find the split, cut the wires here. Install two 30 amp 4 pin relays (if you have room, above the voltage regulator horn relay on the back side of the radiator saddle), preferably water proof. One relay is for the low beam and the other is for the high beam. Sort out which wire is for high beam and low beam.

Then run the low beam wire that is from the headlight switch to the No. 86 pin on one relay and the high beam wire to the No. 86 pin on the other relay. You may have to extend the wires slightly to reach the relays.

Run a ground wire to each of the No. 85 pins. Then run two 12 gauge hot wires from the battery, with water proof 20 amp inline fuses, to each of the No. 30 pins.

Finally, connect each of the high and low beam wires that go to the bulbs to the No. 87 pins (both high beam wires to one relay and the other low beam wires to the other relay). Want to do it even better, run new larger 14 gauge wires to the bulbs.

Once its all wired up, test it. The headlight switch will now trigger the relays, and the relays will feed the bulbs a full 12 volts and a much brighter headlight (no parasitic loss through the headlight and high beam switch, and small stock headlight wires). If it works like is should, tape it all up like factory and you are all set. Its a really great conversion and one that makes driving these old trucks at night much safer for both driver and others on the road.

Last edited by Dragsix; Wed Oct 30 2019 03:06 PM.

Re: '58 Apache headlight relay install....
cjoe #1333280 Mon Nov 11 2019 04:23 AM
Joined: Feb 2010
Posts: 133
Shop Shark
Go to Summit and get some LED bulbs.... that reminds me I need to do that!

Ed Miller
'58 Apache short Fleetside half ton Napco
Falls City, OR

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