Hi Dan, I figure your the man for these questions, so here it goes.
Background: I bought your relay kit for lighting. I don't need super bright lights, but want to safeguard the lighting switch. Car: 65 Dart, stock.

1) What is the gauge of the stock wires for the headlights?
2) You suggest running the relay power directly off the alternator. I assume the alt. in internally rectified to DC, but how is it regulated down? Isn't the regulator bypassed in this hookup?
3) I intend on using the stock lighting sockets for now, only because I plan on regular intensity bulbs. What is a safe maximum bulb wattage on stock wiring?

On the NEXT car (73 Dart) I'm going to go with hot lighting and will need to upgrade to the ceramic sockets and heavier gauge wire. What is the gauge you recomend? what is the safe maxium bulb wattage on the larger guage wiring?

thanks!!!!!

Most of the time you "don't need" seatbelts, either. Until you suddenly do. Do you drive at night? Then you need good headlamps.
Way too thin for efficient power handling.
No. The alternator B+ terminal and the battery positive terminal are electrically common with each other. The regulator doesn't work like a throttle valve on the alternator output.
Poor plan. The relay kit contains new headlamp sockets for use with large-gauge wire. Use them.
What, you want a number below which your wiring won't turn into charcoal? Gimme a break. Don't be lazy. You bought the parts, now do the job right.
You need to upgrade THIS car, you just seem not to realize it.
12ga.

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Too many people who were born on third base actually believe they've hit a triple.

Thanks Dan,

Yes, I have the parts, yes....I WAS being lazy. I just picked up the wire this morning to complete the headlight relay mod correctly.

The stock wiring off the HL switch will be the trigger for the relay only. Its just a mild pain to route the new sockets into the HL position in the early Abodies due to the relatively sealed HL bucket area.

Yes, the stereo sub is an overkill, obnoxious thing. Not my choice. Its a long story. That being said, I'm yielding to my teenage assistants who want to install it. Come summer, it will be removed and I'll get my trunk space back.

I like the idea of the larger alternator, but worry about the ammeter (for now). In Sept., the car will be mostly disassembled and rebuilt. That includes dash removal and correct ammeter upgrade. But to get through the summer driving season, I like the idea of the B+ to battery direct line, just to be safe.

I just finished up the headlight relay mod on the 65 Dart.

I made a complete new harness using Dan's kit. Very complete w/ good instructions. Hots right off the battery, grounds right to the battery, switching current off the OEM wires - easy.

Now off to find some H6024NH bulbs!