Headlight Toggle Switch?

Electrical and Ignition

  1. Red_Duster

    Red_Duster Well-Known Member

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    Good morning!
    Building a custom gauge cluster and was trying to come up with some work around for the headlight switch. Looking at the diagrams, it looks like the full 12V runs unfused through the factory switch? Has anyone ever replaced it with a toggle? If so, what amperage would that need? I was considering the same for the wiper switch? Its a two-speed so maybe and On/Off/On? A quick search didn't come back with anything.

    Not an electrical engineer, so don't even know if this is feasible.
     
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    • Red_Duster

      Red_Duster Well-Known Member

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      And I know that doing this I will lose the dimmer switch, but that would be ok with me.
       
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      • TrailBeast

        TrailBeast Slightly Twisted Member

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        Add up the amps of your dash, headlights, markers and tail lights and that will tell you the amps you are dealing with.
        Figure one 1157 tail light is 2 amps and you will be safe.
        Brake lights and signals are on a different circuit, so those don't apply to your intended application.
        (2 headlights on hi beam, two tail lights, possible front and side markers plus dash lighting)

        A toggle on say 25 amps is going to get hot, so consider a relay that your toggle operates.
        FYI, a fused 30 amp relay switched by your toggle should be plenty.
        The amp rating of your toggle can be pretty low, like as low as a couple of amps, because all it will be doing is turning the relay on and off.
        The relay will handle the load of the lights.
         
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        • Red_Duster

          Red_Duster Well-Known Member

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          Great, thank you. I just reached out to Crackedback about his relay harness. If I am understanding correctly, I would be able to use that setup with a toggle?
           
        • TrailBeast

          TrailBeast Slightly Twisted Member

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          Absolutely, and I was thinking how close to that you were going to be by the time you got done.
          One thought is if you install the relay kit for the headlights you would need two relays anyway (which the kit has)
          (Toggle turns on the main power supply and the hi/lo switches either the hi beam relay on or the low beam relay.)
          This will take ALL those amps off your factory wiring, and not only give you way brighter headlights, but more power available for everything else electrical.
          You signals, wipers and heater blower will all slow less with the headlights on at idle.
           
        • Cuda Al

          Cuda Al Well-Known Member

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          There are On-On-On toggle switches out there, I had one on a truck with three tanks, Left-Center-Right.
          The switch is unusual but can be used as a Off-On-On. They look like a typical DPDT switch but are different internally and typically have a jumper between two terminals.


          Alan
           
        • AJ/FormS

          AJ/FormS 68 B'cuda fb, Form S clone ... 367/A833/3.55s FABO Gold Member

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          relays are the bee's knees cuz you can leave the factory wiring alone and just put the relays at the devices, bringing a hi-gauge wire there.
          Just don't put a regular fuse in the headlight circuit, cuz if it pops at 3Am at 65mph on a moonless night,then things could get real exciting real fast.
           
        • KitCarlson

          KitCarlson Well-Known Member

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          I used a MicroSwitch 4TL1-1E like this on a kitcar, it has detent for center off. It also controls raise and lower of headlight buckets. High/low on floor switch, instrument lights an separate switch. Expensive, and large, but good and reliable.

          shopping.jpeg
           
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          • RedFish

            RedFish Well-Known Member

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            Just F.Y.I. There are 2 supplies to the factory headlight switch. B1 feeds the headlights. Although there isn't a fuse, there is a cycling circuit breaker built into the switch. So if there is a fault the lamps will operate on and off rather than leave us fumbling for a replacement fuse in the dark.
            B2 feeds the park lamp circuit and is fused to protect those smaller wires. So... 2 toggle switches? Good luck with it
             
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            • 67Dart273

              67Dart273 Well-Known Member

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              Consider some options. Use relays, you need two. One for high beam, one for low. YOU NEED NOT "lose" the dimmer switch. the headlight power goes to the dimmer, which then switches between high and low

              Consider a center off DPDT switch. That means "double pole double throw"

              The "double pole" part essentially means it is two switches in one. "Center off" means just that, it has left, center, right or up, center down Double throw means it is "one" to separate circuits each side of center

              HERE IS WHAT YOU DO.

              Wire center of one pole to the tail circuit fuse (originally to the HL switch for the tail/ park/ dash.

              Wire the two outer terminals together and run that off to your tail/ park/ dash stuff. This means the switch is off centered, and those circuits will be live with switch either up or down

              Now wire your HL power to the other center terminal. Wire the outgoing switch HL power TO ONLY ONE of the other terminals. Run that to your dimmer switch, run the high and low beam output to trigger two relays, and run their outputs to the lamps

              This means the switch will be center off. One way (down?) with be tail/ park/ dash only. Other way (up?) will be those plus the headlights as well
               
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              • 67Dart273

                67Dart273 Well-Known Member

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                This is just one type of center off, DPDT switch. 6 terminals

                Z-s2s0qcpEx_.jpg
                 
              • crackedback

                crackedback FABO Gold Member FABO Gold Member

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                JMO, Set it up so the power runs from the toggle through your dimmer switch for hi/lo control. With relays the load on your toggle will be minimal, less than 1/2 amp in most cases.
                 
              • Red_Duster

                Red_Duster Well-Known Member

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                Your guys are awesome. Going to pay for those relays in the morning
                 
              • Red_Duster

                Red_Duster Well-Known Member

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                Alright! Relays are on order and I picked up the DPDT switches yesterday. @67Dart273, could I use a similar wiring setup for the 2 speed wiper motor? Up high, down low center off? I’m thinking yes?
                 
              • 67Dart273

                67Dart273 Well-Known Member

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                That is a bit trickier. Those switches are tricky. You might pull it off and lose park, etc. Best thing to do is get (download) a few shop manuals and real the electrical (section 8) pertaining to wipers.
                 
              • Red_Duster

                Red_Duster Well-Known Member

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                Ok! Ready to tackle this project. The relays should be here later this week, and I have the switch. dpdt-on-off-on jpg.jpg

                Trying to simplify this, and leave it for the next guy. If I am understanding correctly:
                - switch pole #2 will run to the tail circuit fuse. I believe this is the B2 blade on the factory switch.
                - switch pole #5 will be HL power which I believe is B1 on the factory switch.
                - switch pole #1 jumped to switch pole #3 will be tail/park/dash, or I and R on factory switch.
                - switch pole #4 will be headlights, H blade on factory switch.

                I think the only thing I am missing is the dome light... not sure how to do that one yet... mini toggle under the dash?
                 
              • Red_Duster

                Red_Duster Well-Known Member

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                @67Dart273, as the resident expert on all things electronic, does that sound about right to you?
                 
              • kursplat

                kursplat FABO Gold Member FABO Gold Member

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                DSCF7113.jpg

                e-bodies have toggles
                 
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