Halogen headlights in a classic Mustang

I put Halogen headlights in my '67 years ago.  This summer the lights went out when I was on high beam.  Since then, I have only used low beam and had no problem.  I remember something from a back issue of Mustang Monthly about changing to a Cougar headlight switch because they had a higher current rating on the internal circuit breaker, sometimes required by Halogen lights.  Does anyone remember from what year Cougar?  or where to find the article, as I have a lot of back issues.  

Recently the lights blinked out on dim too.  I went through many back issues of Mustang Monthly but couldn't find the reference back.  As I ran for several years without problems, I just ordered a stock replacement switch from one of the Mustang vendors out there.  

I just bought a set of those lights to go in my 66, wish someone would pipe in here & tell us a bit more about the wireing part of it.  

Can't help you on the Cougar year, Try replacing the dimmer switch on the floor since it controls the light output from the headlight switch to the lamps.  

Why not do the relay conversion and never have that problem again ?
I have 100/140 watt H4's in  my Bosch Lights

There are several Made up wiring kits available but I made my own for $20.00
They make your lights more efficient and the switch will never fail again
Here is a link to a bronco.. same thing different pile

http://www.danielsternlighting.com/tech/relays/relays.html  
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"So that is how you shine a skunk ? "

Bluejay, the problem that you are experiencing is common. The headlight switch has an internal bimetal strip (circuit breaker). This is used in place of a fuse, because, if you have a short, the lights will only go out for a short time before the circuit breaker resets itself, thus turning the lights back on, if only for a few moments until the short or problem is fixed. Now, the halogen and xenon headlight draws more current than a standard sealed beam. With halogen or higher wattage lights you are approaching or exceeding the limits of the internal circuit breaker. The best solution would be to replace your old switch with a new switch, the new switch’s breaker may be strong enough to handle the extra load, if not then wire in a relay.  
Mustang enthusiast since 1973.

Hi bluejay/sorensen66 - I installed Halogen headlights on my 66 two years ago and utilized a Halogen headlight relay kit from one of the local Mustang parts suppliers. You can buy relay kits for $30-$40 and they install between the light switch and the headlights. There are two relays, one each for low/high beams. They come with instructions for wiring so as long as you follow the instructions and splice in the correct wires from the headlight harness you can't go wrong. It took me a half hour and it's been trouble free. I can now see twice as far and my field of view is wider and much clearer. Not to mention I no longer worry about people seeing me.  I installed the relays on the driver’s side behind the washer bag so unless you move the bag you'd never know. I'll take a photo tonight and post it here for you.  

Sorry for the delay in getting this photo here - it's been a long couple weeks!
 

scott66GT

Hey can you tell me where you got your kit?  I checked the source I normally use and the kit is like $140.  It looks like the same as in your photo.  Thanks  

I've run halogen headlights in my '66 GT for the last 6 six years with a repro headlight switch and repro dimmer switch from a Mustang parts house with no problemo. Even with the fog lights on at the same time as headlights....no problemo.
Also ran a '65 Fastback the same way for 15 years with no problemo.
Maybe I was lucky....twice.  

you must use a relay for the high and low beam ,ben using Cibea & Hella since the 70's with relays and 95/100 H4 bulbs no problem,headlight switch has built-in auto reset circut breaker.  

Hi 67ConvertibleGuy, I got mine from Mustang Depot of Las Vegas (home), 702-262-0011.  Item Code: MD-HDRK, 64-68 Headlight Relay Kit, $43.06 in Nov 07.  No problems at all.  It included instructions for install and was in in a 1/2 hour.  

I did this to my '66, bought the parts separately at Napa.  I wasn't crazy about being able to see the bare wires and relays on the fender apron, so I used the old voltage regulator base and cover (removed the internals) and painted it black like the engine compartment, mounted it below the windshield washer bag.  I used the original non-adhesive tape (from NPD) to incorporate the new wiring into the wiring harness.  The splice is hidden behind the washer bag.  I routed the power lead through the front crossmember up to the starter relay.  It works great and you really have to know what you're looking for to find it!  
Second owner
'66 C Code Coupe
(A Family Affair)