Here is the ground wire that melted going to the relay, But the +12V ign switched source was not hot/or even hot when the ignition was turned on, verified that today with my digi multimeter..

You can't really see it that well but there are 4 open wires in there, wtf?

I checked the relays, they are good. This is what I believe happened; when the relay was given power, it grounded the power to complete the circuit as usual, and the ground wire was too small, 16awg, while the power wire was larger either 14-12awg. The ground wire couldn't handle all the juice and fried, along with all the wires it was next too. So why the hell did haltech make the ground wire so small? https://www.nopistons.com/forums/pub...R#>/unsure.png

good question. But if you got it all apart rewire it with larger ground

Well if Haltech doesn't compensate me, I will rewire it with a much larger wire, and I will rewire all grounds/power wires outstide the main harness and have inline fuses put in.

did you have it fused correctly?

I burnt out my plow headlights switch, melted it beyond recognition

first time I wired it all up because I used too heavy of a power wire and

had too big of a fuse. Sometimes bigger isnt better. But its always better to have

a heavy ground.

Yes. It had all the fuses on it, and none of them blew... https://www.nopistons.com/forums/pub..._DIR#>/sad.png

maybe the fuses are to big?

they came with the haltech, they are between 25-30amp I believe, Does anyone know off hand how many amps each size wire can handle? I need to know for reconstruction...

why would so many amps being traveling throught the wires anyhow? What determines how many amps is going through the circuit anyhow? Doesn't whatever is doing the pulling, ie: efan determine that? But what about in this case...