Briefing:
I was tired of the headlights under-performing and decided to do something about them. At first I thought the problem was in the bulbs so I used super bright PIAA bulbs but the difference was very marginal. When I measured how much voltage the sockets were receiving, I was not surprised. There was a marginal voltage drop in the bulb sockets which explains why the bulbs don't work as bright as they should. The reason for the sockets running low on voltage is that they go through the tiny switch in the stalk and are powered by thin gauge wire which is not ideal for 65/45 bulbs. According to some math, the minimum wire gauge that should be run to those light bulbs for the distance of about 20 feet is 14 gauge. The factory Nissan wiring would only work if the wiring was under 10 feet long but it is not! See: http://www.amplepower.com/primer/gauge/index.html The way to solve this problem is to relay the wiring directly to the battery. A relay in this situation will take small power from the connectors and connect the power from the battery to the headlights. After looking around at some relay harnesses, I was not happy with any of them. They were still thin gauge wires with crappy Chinese relays. Unable to find anything decent and something that fit at the same time I decided to build my own harness which will use factory Nissan relays.
Required items:
2x High Temp Ceramic Male 9004 Connectors
1x Generic Female 9004 Connector
1x 14 or lower AWG triple conductor loop of wire, about 20 feet
1x Inline Fuse Holder with 20-30 Amp fuse
2x Ring Terminals
8x Quick Female Terminal Connects
2x Blue Nissan Relays (or 1x Black Nissan Relay)
Also needed:
Soldering Gun
Heat Shrink Tubes
Wire Loom
Electrical Tape
Wire Cutters/Strippers
You can also get one of these "upgrade harnesses" to get the proper plugs:
Here are some pictures of what I had:
The harness is not yet complete but it should be soon and I will post before and after photos.