I've been doing a lot of research on wiring harness for the H4 conversion housings and 55/100W bulbs I just bought (not so much because the current set up cannot handle it, but I'd rather not run 100 watts from the battery through the light switch on the steering column then back out to the head lamps if I can help it; I assume a '91 4Runner is still a switched ground like some of the older trucks).

Right now my options look like 4Crawler's harness (complete, simple plug and play installation, ~$40) or a kit from Daniel Stern Lighting (~$70), RallyLights.com no longer offers a switched ground harness. The Daniel Stern product has the appearance of quality but the "kit" only includes the necessary hardware (includes "American and German-made extreme-duty parts" such as relays, fuses, terminals, etc) but it contains no wire; which ultimately means that I'm sourcing my own 10-12 ga wire (which they recommend yet it seems excessive) and doing the labor myself, all for nearly double the cost of 4Crawler's.

Now in one of their "technical articles" Daniel Stern Lighting makes a reference to quality products vs cheap/in-expensive products, namely relays, but in a circuit with 2 relays (possibly as many as 4) to justify that kind of price difference those relay's must either be made by God himself or they're over-priced.

A quick google search revealed a 12V 30A Bosch Relay (SPDT) for under $3.00, and from what I've gathered Bosch is a very reputable company with quality products, so I'm not really sure how Daniel Stern Lighting came up with this price.

So now my question to all of you, should I go with 4Crawler's, email/call Daniel Stern Lighting and ask about there's, make my own from wiring diagrams I've found online (and some general electrical knowledge I have), or from some place else I don't know of yet.

BTW, Daniel Stern Lighting's website has a lot of interesting reading, I just found the harness kit pricing a little strange.

Thanks for any help, and sorry about the long post.

 

I have 4crawlers wiring harness in both of my vehicle, definately a high quality item, go with them! I have many different electrical addons, including a 24 volt system for my air horns, in my truck and have delt with an alternator putting out 17 volts, and nothing has hurt that thing. go for it

 

If you are cable of putting together a quality wiring harness and can source all the parts, then by all means make your own. You can tailor it to your exact needs. You'll have to modify any of Stern's wiring diagrams to work with the switched ground wiring in the Toyota:
- http://www.4crawler.com/4x4/CheapTri...shtml#TechInfo

And note the "Bosch relay" is sort of a generic name these days. More defines the form factor and terminal layout than the actual maker of the relay. And even buying a relay from a US or German mfg. often results in a product made in Taiwan or China these days.

I run one of my harnesses in both my rigs, they have worked fine for the 4-5 years I have had them installed.

 

4Crawler seems to make good stuff, otherwise he wouldn't be selling it to you.
At 100W x 2 = 200 watts.
P=IV (current * volts):
200= Amps * 12.5 (operating voltage), So you're pulling 16amps.
My experience with alternate lighting says if you're getting up there towards the limits of the rating of the relay, go a step up - or do a pair.
If I'm pulling 16 amps, I typically run a 30 amp relay, or 2 x 20 amp relays...

I'll let you do the homework on the correct gauge of the wire, just make sure to insulate it.. Stuff vibrates/rubs/blah blah.

Recently I've started using 70A relays for offroad lighting. Overkill, probably, but I'll drive 400-500 watts of lights off a single relay. Keeps things neat.. GM "weatherpack" connectors are pretty sweet, if somewhat pricey... Try 'em if you get your junk in the mud/snow/water/ice. I also like using stainless marine fuse boxes as a distribution and fuse point before the relays.