I'm wiring an HID kit into my driving lights and the plugs from the HID globe are too large to fit through the hole in the rear casing. I don't want to enlarge the holes in the lights at all.

Is there any problem cutting the wire, feeding through the hole and then rejoining using terminals/joiners?

Ok I was going to extend the leads myself so I can get the ballasts under the bonnet but these extension leads were so bloody cheap I got them instead.

HID Extension high voltage wire cable wiring 1M ballast - eBay Headlights, Lights, Indicators, Car Parts, Accessories, Cars, Bikes, Boats. (end time 06-May-10 21:12:32 AEST)


Still doesn't solve the joining issue.

V-IN: 9-16 V
V-Norm: 13.5 V
I-Norm: 3.2 A
I-in max: 10 A
P-Out 35W norm
V-Out 23kV max

Surely any spade terminal or block connector could handle that? The current at 23kV would be SFA??

Ok no cutting

YouTube- When HID ballasts go bad #2
Big drillbit into beautiful driving lights

The instructions for the Lightforce HID Kit warn against cutting the wires in big letters:

http://www.lightforce.net.au/files/p...20HID_INST.pdf

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Ex 300Tdi Disco:

No way I would cut the high voltage wires and rejoin them. Would you do that with spark plug leads?
When I fitted a HID kit to my friend's spotlights he didn't want to drill a big hole in his pretty lights either so we trimmed the connectors down a bit and changed the wiring so the 12v wiring didn't have to go into the light housing.

Shoot I would feel the same way haha, I wouldn't want to drill some holes in them.

Most of those connectors you can pull the pin out of the connector then push them back in once through a small hole. It is a while since I did one, so can't quite remember which bit to push/lever and in what direction down in the connector to release the pin, but it should not be too hard to work out

Its the voltage you have to be concerned with, and the insulation needed to stop 23kV from jumping to ground.
Have you looked at removing the connectors to get the wires through the small hole?

Steve.

Good Lord, what shall we dredge up next, the Roman Baths? (he jokes)

I tried removing the plugs, there's a knack to it and I ended up rooting half the cables/globes. In the end I bought a slimline HID kit and all the crap fits perfectly in the light body, only the ordinary low voltage leads emerge, it's all very neat.