Finished - with pics
So I have it all wrapped up at this point and the final results are fantastic. My goal with the project was to get everything installed with no cutting and splicing on the foglight aftermarket harness and factory wiring. It has been my preference to not cut anything since a driving light install went poorly on an '84 GTI Rabbit I owned...
Anyway, this was achieved using some additional 9006 ceramic extension connectors ($20 for 4) and a 9006 connector with pigtail leads ($10). All of my wiring and connectors were sourced from eBay. I chose domestic sellers for all the wiring for speed and accountability if anything had been wrong with them. I had absolutely NO problems with any of the parts listed below and everything works perfectly. I also installed some of the amber Lamin-X cover material ($20) for protection and glare reduction in snow storms (I live in Maine and drive a lot). All told here's the cost breakdown:
Foglights and grills -- $80 (China)
Euro switch -- $33 (China)
Wiring harness -- $8 (domestic)
Lamin-X covers -- $20 (domestic)
9006 ceramic ext -- $20 (domestic)
9006 pigtail ext -- $10 (domestic)
TOTAL -- -- $151 complete
This is the passenger side fog shown from behind with the additional ceramic connectors hooked up, the driver's side has the same additional double connector setup. I could have spliced additional wire into the harness but I like the additional connectors better for fit, finish and ease of removal when taking off the bumper. They are durable and weather-tight.
Connector-ized trigger/ground leads. The black/white wires are from the relay on the harness, the red/black in the loom on the left are the pigtail 9006 connector I bought to hook it up. The pigtails had male spade connectors on the lead ends so it was a simple matter to install female spade connectors on the end of the trigger wire from the interior switch and on the ground lead pictured previously to connect everything with no splicing. Again: durable and weather-tight and easy to disconnect if needed.
Fabricated mounting post point for harness relay and fuse, top view with airbox corner in upper left of photo and electric box in lower right. I drilled a small hole in the airbox and used a short bolt with a fender washer inside and a spacer and small nut outside. The thin black plastic is a piece of LCD TV wire loom strapping that was cut to the correct length to mount the fuse on one end and the relay on the other, it just happened to be the correct width to fit into the slots on the back of each. The tiny yellow zip tie keeps the relay from sliding off the strapping by slotting through it on the end. ** update: I replaced the relay in the photo with a comparable relay that has a metal mounting tab attached rather than the plastic slot built into the case, it works much better **
Different angle showing the stand-off post and strapping assembly I fabbed. The ragged looking slot on the right end of the strapping is what the tiny yellow zip tie slots through after the relay is mounted.
Ground point I used, shown with bumper removed, this is directly under the driver's side headlight assembly. It had nothing connected and was easier to reach than the primary factory ground point you see next to it on the right with some factory brown ground wires connected.
Low angle, just above the ground from approximately 8 ft away
As mentioned in a previous post, I also used the empty power post that is furthest outboard on the front of the fuse box under the cover. I didn't take a photo because it is obvious which is the empty one.
Thanks to ESFlash for the original post and some helpful wiring tips along the way and to my daughter who held up the bumper before re-installation while I connected everything.
** update: after driving with these for the past week, both before sunrise and after dusk, and doing a little bit of aiming to lift and flatten out the direction versus pointing down 20' in front of the car as they were aimed out of the box, they really enhance back-road visibility dramatically. Driving home from work tonight on a twisty, dark, back county road I can earnestly say that they improve overall visibility greatly, especially into corners and over blind rises in the road. I like the fact that they stay on with the high-beams because they really flood the area in front of the car with lots of light. I didn't realize how much illumination was missing from the stock headlights until seeing these in action with my own eyes. Highly recommended install on US cars! **