I have been having some electrical issues

[Paul G]

I have been dealing with low voltage at idle, CD player cutting out when I put the turn signals on, A/C on makes the lights very dim at idle, etc. I decided to run a new 8 gauge wire from the alternator to the wiring harness under the dash. This is what I found at the bulkhead connector. The second terminal down from the top on left. The connection was ready to burn open! I am so glad I decided to do this.

[FLG]

Nice save...actually made me just walk out side and check mine.....seems to be fine.

[Nacho-RT74]

tipical... I think you know what thread to check ( clue: one I started some time ago )

[Paul G]

I decided to do the headlight relay upgrade while I am doing this. I made up a relay block with three relays (first pic). One for the dim lights, one for the brights, and an extra one for the electric cooling fan I have in mind for later. I found a place to hide the relays behind the driver side headlights up high on existing screws. (second pic)

I mounted a new 6 circuit fuse block next to the factory fuse block under the dash. I ran that new 8 gauge wire from the alternator to the new fuse block main terminal. The original factory wire that feeds the old fuse block and accessories is soldered on to the new 8 gauge wire.

I will have the new fuse block supply the power for the headlights through the new relays (switching over to halogen headlights someday). The relays take the headlight current off of the headlight switch.

The HVAC circuit fuse in the original fuse box burned up a long time ago. The HVAC circuit is a large current user also. Since it uses switched power from the ignition switch, it will now be fed through a relay under the dash that will energize from the ACC position of the ignition switch.  The relay switched circuit will be fed from the new fuse block. I fed the CD player from the new circuit block now too.

The next thing will be the alternator. Either a Powermaster or switch to a late model Denso.

I have been thinking about adding an electric "pusher" cooling fan in front of the A/C coil to help out in the summer. There was no way the electrical system would have been able to handle that before.   

[Nacho-RT74]

http://www.dodgecharger.com/forum/index.php/topic,33574.0.html

[Paul G]

That is a very good thread you have there Nacho. That should be stickied to this section.

You mention in that thread that later alternators put out more charge current at idle than ours do. What years of alternator will put out more current at idle? 

[Nacho-RT74]

any year ( lates 70s, eraliers 80s ) as far is with that looks ( not visible stator ) and comes from a fully equipped car. The newer, the better.

[71_deputy]

best upgrade you can do- mines still works and brighter lights for the last 5 years.

note: use dialectic grease on all the connections of the relays!!!!