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. 

29 AUG 2026 - Automotive Electrical Wiring

 The Deutsch DT series of connectors is ideal for headlights, headlight actuators.

 While installing the connectors to the wiring loom of the electric headlight actuator kit, I damaged two pins on the 4 pin connector on the driver side headlight actuator.  Ordered a Deutsch DT kit with a crimper.  I will rewire the actuators and wiring loom of the electric head light conversion kit and use Deutsch DT 4 pin connectors.  The Deutsch DT kit will be here in a couple of days or so. 

20 AUG 2026 - Electric Headlight Conversion Kit for 67-68 Mercury Cougar

 Last week I ordered an electric headlight conversion kit for the 67.  It arrived yesterday.  Package contects are a left and right actuator, and a main wiring loom.  No instructions.  Don't see that as a big deal right now, it looks pretty straight forward to install.

  

2 May 2026 - Radio Bezel

 Recently purchased a replacement radio bezel from national parts depot.  I do not have a radio that fits that bezel.  I created an insert in the area where the radio would be installed.  Now I can store the garage opener, radio remote in that spot.  I also created two inserts to cover the location of the radio knobs.

 Working on scanning the dash area to create a replacement radio bezel.  Current scans are not promising, so I'll have to spend more time on scanning techniques.