Description
Upgrade your classic vehicle’s lighting performance with the plugpal Headlight Relay Kit – a professional solution designed to deliver brighter headlights while protecting ageing switchgear and wiring.
Many classic cars route full headlight current directly through the dashboard and column switches. Over time, this can cause voltage drop, overheating, dim lights and premature switch failure. The plugpal relay kit solves this by redirecting power directly from the battery to the headlight bulbs via heavy-duty relays.
Why Fit a Headlight Relay Kit?
Installing relays provides multiple key benefits:
- Brighter, stronger headlights due to reduced voltage drop
- Improved lighting stability at night
- Reduced load on original headlight switches
- Extended lifespan of expensive or hard-to-source switches
- Improved overall electrical efficiency
This upgrade is especially valuable for classic cars where factory wiring was not designed for modern driving conditions.
Dual Relay & Fuse Protection
The plugpal kit features:
- Two pre-wired 40amp relays – one for main beam and one for dipped beam
- Separate 20A fuse protection for each beam circuit
- Integrated covered relay and fuse box for neat, protected installation
By splitting the circuits, both high beam and low beam are independently protected for added safety and reliability.
Heavy-Duty Automotive Wiring
This headlight relay kit is built using quality automotive-grade thinwall cable:
- 16.5A PVC thinwall cable for loom switch connections
- 25A PVC thinwall cable for battery feed, earth, and headlight supply
- Crimped (not soldered) terminals to prevent vibration-related stress fractures
- Approx. 1 metre cable length, suitable for most installations
- Split PET braided sheathing for abrasion protection
- Sheathing can be trimmed back easily if a shorter loom is required
- Box measures 70mm x 70mm x 80mm (WxDxH)
The result is a durable, high-capacity wiring upgrade designed for classic vehicle electrical systems.
Complete Installation Hardware Included
To ensure straightforward installation, the kit includes:
- 4 × Lucas bullet connectors
- 2 × Lucas bullet connector joiners
- Ring crimp terminal
- 6.3mm female crimp with protective cover
- 6.3mm piggyback terminal
- Spare fuse terminals so you can add additional fused circuits
Everything required to integrate the relay kit into your existing wiring loom is supplied.
The Essential Lighting Upgrade for Classic Cars
Whether you’re restoring a vintage vehicle or improving night-time driving safety, the plugpal Headlight Relay Kit delivers brighter headlights, reduced electrical strain and improved reliability.
Protect your classic car’s switches and maximise headlight performance with a professionally designed relay conversion kit.
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