One of my design rules is that it has to be reversible in case of selling the car or any unforseen need to get back to DOT standards.

I recently was forced to do a rudimentary single-relay upgrade on the car, due to main relay on kick panel starting to overheat. I postponed the full multi-relay job for after instlalation of the two 6x8s, which are now installed. I installed the one relay before the signal input into the step relay. So low power arrives at the original relay connector but full power goes into the step relay from new relay, to be routed by the OEM system.

My current plan for a proper relay upgrade is to remove the temporary setup (above), then have the new relays signaled by the two output wires from the step relay (behind battery). Doing this cleanly requires a new connector for that side of that relay (it has two connectors). The output wires will each go to a relay which sends full power to the headlights. The (3rd) input lead will just need a wire with male and female spade tips to bring in the "power", now a signal, from the existing connector to the step relay.

I hadn't long considered running the relays off the 9004 plug connectors. This would require two relays at each headlight but gets you out of wrestling with the step relay and its connectors. The step relay is a bit of a bugaboo because it's tight quarters in that location next to the p/s reservoir.

The 9004 plug connectors have very narrow slots that don't match any spade lugs I could find. I currently have small spade lugs, filed down narrower, slipped into them, feeding my DOT bulbs. Not the best, but OK for temporary use. One could either fabricate a male connector from a dead 9004 bulb or cut off the female connector and crimp on whatever you want to use. If you want to run relays off those connectors.

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Sven: '89 245, IPD sways, electric rad. fan conversion, 28+ mpg - auto tranny. 850 mi/week commute. '89 245 #2 (wifemobile). '90 244 (spare, runs).