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  #1  
Old 05-24-2010, 11:57 PM
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Default How-To: Wire up Hella 500's Behind grill

I finally got the Hella 500's, after months of wanting them the woman finally bought me a pair! right behind the grill is where i want them!
With scouring the forums there seems to be alot of people with them, with pics, but no other details as to how they were wired! this should help out alot of people!

1. This is what i started with...wring harness lights, some connectors and switch!

2. Next i drilled the holes for the mounting of the lights...they were 3.5" in from each brace on either side of the bar in front of the rads, i used a 3/8 drill bit and slight chainsaw file to open it up a little more and they slid right in!

3. After they were all bolted in i need to found a ground, some round connectors that didn't come with the kit were used, the inside bolt on either side of the mounting bar worked perfectly

4. The easy part was is now done, next was to wire up the harness and mount the relay

5. Mounted the relay to the right hand side, upper bolt of brake master cylinder
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  #2  
Old 05-24-2010, 11:57 PM
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6. I ran the power for the relay (red wire) to the same tap off the fuse block, it follows my amp power wire! the blue relay ground is run straight to the negative terminal on the battery!

7. The yellow relay switch wire is run through the firewall at the same spot my amp power wire is, the second pic shows it on the other side, 2 buts remove the plate to make it easy to drill a hole through!


8. So now the last wire coming from the relay should be black, the rest should be connected, an yellow should be in the cab. the black is then run in behind the battery to the front, and down the driver side pillar beside the headlight mounting. then i cut to length the wire and crimped it together and taped up all the wires to give it a nice clean look!

9. Next i decided where i would want my switch to be, under the headlight cluster is where i wanted it, on the dash piece right above my e brake release, so i ran the ground wire(blue) relay switch wire(yellow) and the 12v power wire (green) to this spot, a handy hole was already there, drilled out the dash piece and sanded and filed to get the switch to a very snug fit!

10. to the side i connected the ground wire to part of the metal behind the dash, there are many bolts contacting metal so any of them would do, but the ground wire in the kit is pretty short so this one work fine, its sort of hidden but is the top bolt

11.My original plan was to have the switch 12V power to run off a wire with only ignition power, then i realized i didn't want to hack any wires up under my dash so i ran it directly to the battery positive, and through the fire wall at the same spot as the yellow!

12. Next was to connect the three wires to the switch, which is labeled 1, 2 an 3, 3 being the blue ground wire, 2 is the yellow relay switch, and 1 is the green power wire! put the dash back together and she was done!


Unfortunately i don't have pics of the lights on! i popped the tiny 2A fuse in the green switch wire and don't have a replacement! Being a holiday the parts store is closed so gotta wait till tomorow!
I will have pics on, grill down and up!
Hope this helps some people out, maybe more of you will attempt this mod on your own took me about 4 hours, but i kept changing my mind on where i wanted to the run the wire, and the biggest drill bit i had at home was 3/8 so i think i spent about 1.5 hours sanding a filing the hole big enough for the switch in the dash But its done a they look awesome hiding behind the grill!
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Old 05-24-2010, 11:59 PM
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Nice writeup Ruffian

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Old 05-25-2010, 01:01 PM
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Good how-to write-up
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Old 05-25-2010, 09:51 PM
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Thanks guys! trying to help out the few that want to attempt this on there own!
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Old 05-26-2010, 12:45 AM
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wow so yours worked hooking them up via the destructions???????? i tried 2 diff relays and click click click click..... nothing just flashing lights. wired the mdirect with a properly sized switch and BOOM there was light. i feel jipped but on the upside that was a real good write up
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Old 05-26-2010, 12:57 AM
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Great write up This is good info for people wanting to install lights
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Old 05-26-2010, 01:04 AM
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Ya it worked fine! i popped the fuse in the switch power wire....got a new one and it works fine! just need to get time to aim them properly!
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Old 05-26-2010, 01:11 AM
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Very nice write up man, thanks for taking the time to put that together, definitely a mod I'm interested in doing, those just look awesome! Now, looking forward to those pics!

- Cajun
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Old 05-26-2010, 08:22 AM
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i found on another forum as i was searching to why mine didnt work right that a guy ground down the front part of the plastic housing to get them aimed lower than they sit, im still debating if i want to do that and screw it up and have to buy another set of lights.
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