Headlight Relays

Since I have a one-wire alternator I didn't need the external voltage regulator anymore. This gave me a perfect place to hide the relays for the headlight upgrade.

I found a period correct pre-electronic voltage regulator at the junkyard and gutted the inside. I then cut an access hole in the base for the wiring. Holes were drilled to bolt the relays to the regulator and bead blasted and painted. The regulator's plastic harness connector cover was pop-rivet back in place.

Once half way through this little project I came to the conclusion that I didn't think this through enough. I went back and drilled the screw holes on the relay's mounting tab closer to the relay and snipped the extra length from the mounting tab. Also I drilled new holes to move the relays closer to the edge. This would allow me room to stuff the relays inside the regulator with the wiring harness connectors. A grommet was used to protect the wires from chaffing where they pass through the regulator base. I gutted a new voltage regulator pigtail connector to pass the wires through the plastic connector and with the help of hot glue to keep the wire from falling out to make it look like it really is plugged into the regulator.

With a new blue paint job and a reproduction Motorcraft decal the new-old regulator can now be put back in the original location. Someone who didn't know better might not notice the extra and wrong color wires.