9 SEP 2026 - Radiator

 While installing the electric headlight conversion kit, I discovered that the radiator has a leak on the passenger side lower corner.  Looks like maybe the lower radiator outlet is leaking at the radiator.

 So, before it gets worse, I will begin purchasing components to replace the radiator.

• I already have a replacement 3 row aluminum radiator.
• AN6 fittings/adapters - hard line to AN6 male ends - two   
• water pump fan spacer - not sure of thickness yet, radiator needs to be installed to check
• two AN6 double male end hoses for the transmission to radiator connections.
• Upper and lower radiator hoses and clamps
• transmission fluid
• radiator fluid 

7 Sep 2026 - Electric headlight conversion kit

The relay that is used for the kit is a 40 amp SPDT with an LED to indicate status and a mounting tab.

 

 

 

7 Sep 2026 - Electric Headlight Conversion Kit

 The passenger side wiring harness needs to be shortened about 24" and re-terminated. 

 While that section of the harness is removed, I can remove the +12 volt wire and properly wrap with a plastic wiring loom cover and use tessa tape to seal things up.

 The mounting location of the control relay is good but the wiring for the trigger wire from the car harness and the kit harness needs to be re done to tidy up the wiring.

 All runs of the wire loom need zip tie mounting tabs as well as using zip ties to secure kit harness to stock wiring harness.

 Need to get better battery terminal blocks that have taps for the various +12 and ground connections. 

6 Sep 2026 - Electric Headlight Conversion

Today the installation was completed.  The kit works very well.  I adjusted the headlight doors to align them to each grille.  Tie wrapped the kitcwiring loom to the frame.  I connected the battery, started up the cougar then went for a test drive.  Test drive was about 15 minutes, everything checked out good.  I still need to setup the headlight wiring looms so they do not get caught up in the actuator's movement.

5 SEP 2026 - Electric Headlight Conversion Kit

 Found out that both battery terminals and battery cable terminals had just enough corrosion to prevent functioning of the electric headlight actuators.  After cleaning up the battery terminals and battery cable terminals the kit worked.

 Installed the actuators, and installed and connected the wiring harness.  The engine bay headlight relay power wire was re-terminated with a two pin Deutsch connector that is connected to the blue trigger wire which has a corresponding two pin Deutsch connector. The ground wire for the harness is attached at the top mount of the external voltage regulator.  The power wire for the harness is connected to the battery + cable.  The power wire is in a plastic wire loom conduit.

The relay for the harness is fasted to the driver side engine bay just in front of the windshield washer reservoir.

After connecting the battery cables, the kit was tested and it works.  The headlight doors need to be adjusted to take up the slack in the adjustment rods.  The headlight wiring near each actuator needs to be more properly secured, I don't want those wires getting caught up in the actuator rods. 

 

 

3 sep 2026 - Electric Headlight conversion kit

Removed the wiring harness and actuators to test on the work bench.  I used an ATX power supply that I converted to a bench power supply.  I connected the red wire from the harness to +12 and connected the black wire from the harness to ground on the power supply.  The blue wire is the trigger or coil control.  I connected one actuator to the passenger side connector of the wiring harness, then I touched the blue wire to +12.  The actuator worked like it should.  Moved the actuator to the driver side connector of the wiring harness.  Placed the blue wire to +12 and the actuator worked.  Then I did the same process with the other actuator and it worked.  All components of the kit are functional.

1 Sep 2026 - electric headlight conversion kit

 Replaced all weather pack connectors of the kit with Deutsch DT connectors.

 Now I need to connect the components and check functionality.