Headlamp question

The stock wiring is horrible for voltage drop.

The test is a good one, just be careful that you don't energize the wrong terminals. Post about 66, the low beam wire is violet, high beam is red Maybe use a 10 amp fuse in line on your test wire just in case. A bad ground will hamper out as well.

The halogens will usually work better than the old style bulbs. Low voltage is a curse. Light output does not degrade linear to voltage drop. It's exponential, which means output loss is greater than voltage input drop. Hook up a std 12v headlight to a 6 volt source and the output isn't going to be 50% of rated, it will likely barely warm the filament.

Additionally, the relay kits tend to improve light output in the cabin/dash and marker/turns because the headlight load is no longer taxing the system.

For those that are interested, if anybody thinks those cheap relays units are the same quality of products, design or workmanship/end termination as my kits, they are not. There is a reason, MB, BMW and others don't use those chinese relays in their cars. It's not because the tyco/boschs cost more, it's failure rates.