Evolution of my DIY headlights (quad projectors, Xenons, LED DRLs and LED highbeams) by burkart

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Evolution of my DIY headlights (quad projectors, Xenons, LED DRLs and LED highbeams) by burkart

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14 minute read

Evolution of my DIY headlights (quad projectors, Xenons, LED DRLs and LED highbeams)

Compliments of burkart @ www.nasioc.com

sup dudes

I've been working on my headlights almost all year. posting this as a new thread so my experience can help others with DIY lighting mods.

i did a projector highbeam retrofit / custom job earlier this year. i wanted:

- a clean modern look,

- enhanced light output in rural areas / offroad situations,

- complete reliability over the long term,

- premium oem appearance (in traffic etc)

- no external fog or offroad lights marring the look of my front end (PIAA etc rally lights are cool but not what i wanted for this daily driver LGT)

the highbeam projector project...

- took ****ing forever and was messy with glue/headlight parts everywhere

- the halogen 9005 highbeam bulb looked like total **** compared with the HID lowbeam next to it (highbeam looked yellow and cheap)

- light output w/ halogen projector beam brights was barely noticeable over standard lowbeams

- HID's possible for highbeam projector---- but bc they light up slowly, HIDs for highbeams will be no-good. no effective "flash to pass" type of highbeam functionality

What to do?

I decided to go LED for the highbeams, using military-spec Rigid Industries inside my headlights. installing and aiming is a piece of cake. light output is outstanding. i used the 2x2 rigid industries "dually" pair, in flood specification. (vs spot/diffused/other options). they are small, high-quality items -- only downside is cost.

headlights DIY version 1 4x LED flexi side-emitting white strips

headlights DIY version 2 - 6x 48CM LED flexi side-emitting white strips

Headlights DIY version 3 quad projector beams [custom retrofitted J30 big balls]

headlights DIY version 4 - HID upgrade, enhanced aiming and cutoff + 9-LED white spotlight in top corner of lamp as accent

Headlights DIY v5 - Dually 2x2 LED highbeams, xenon 6000k lows, 18-LED vertical blade accent in corner

in summary:

- quality LEDs for highbeams = FAR SUPERIOR to any projector beams (bi-xenons excluded)

- LED quality varies A LOT. the vast majority of the LED automotive light options on amazon and ebay ==> total garbage / bad quality / fast burnout. get a name brand that is waterproof, heat-sinked and plug-n-play to orig wiring

- LED drl's (version 2 especially) = lots of traffic tickets (4 in a month)

- LED drl's / running lights = offer noticeable output improvements in both urban and highway driving

holler with any replies, extra info, or whatever you can contribute

10/4/2012

well, it didnt take long for the cheap LED 'blades' to fail.

one started flickering so i cut the wiring to both.

took some output pics

lowbeams

low + high (yes, the aim is alittle wonky)

lows and highbeams, brake lights engaged

10/9/2012

DIY HONEYCOMB GRILLE + WHITE LED BADGE LIGHT

another day, another mod.

re-did my old DIY honeycomb grille, to replace the Legacy GT one i have now. used a ford crown victoria grille honeycomb [ a $20 donor new ebay], custom snipped then zip-tied thru six drillholes for mounting. sprayed together to a dull flat black via 2000-degree rattle-can paint.

LED grille badge lives on! used the small LED emblem backing - in white + OEM subaru grille badge and chrome surround.

i considered a 4.5" big white LED emblem mount- but it is too big. it looked to me like the Jurassic Park III Mercedes grille star - just huge and unnecessary.

also totted around the idea of an old chrome 3D subaru badge - backlit by white LED. result was alittle iffy

11/8/12

quick update on the headlights.

the side blades that were "white" leds burned out/started flickering so i turned them off.

also, i noticed that the headlamp light 'color' in the output pics seemed different. (one from another, i mean). i was puzzled, but recently resolved and traced the problem to the engine compartment fusebox. the main RH and LH headlight fuses didnt match -- one a 15a and the other a 25a.

OEM was 15a but upping amps to 25 to account for the HID system power draw.

my new thinking on a DIY LED headlight is to put a bunch of SMD LED lightboards around the projector beam area. these 48-LED white SMD boards are marketed as interior dome light replacements. so therefore, they are not weatherproof. this wont be an issue for my application bc they'll be going inside the light assembly.

took some pics of 3 boards - mounted around the projector glass ball (which is off during these pics)

i dunno. the looks it out-there. they are extremely bright, however

11/9/12

big day! i pulled the lights from the car to work on them. most of my other removals have been forced -- either by failing bulbs or other issues.

this one was voluntary.

decided to use four SMD boards per lamp, a 196-LED total DRL. i lit up the highbeams to supplement the DRL for the pics. keep in mind, there would usually be a BAF (Bright AS ****) HID Xenon bulb behind that projector beam / glass semi-circle.

11/11/12

installed!

they look okay, in my opinion. the projector ball seems extra bright with the LED assistance to the HID bulb.

11/14/12

i will think about replacing the shroud around the projector. more likely, i will buy some HID projector glass semi-circles. the HID ones are more convex - aka stick out more like an egg shape.

anyway, i felt silly driving around with the LED panels in my lights. i want to be proud of my DIY stuff, obviously.

i changed tack completely and ripped them all out. Im now finishing the new version - with four big white leds making a square around the projector beam. these things are pretty cool little bulbs. they're each 3W which in LED terms is alot of light.

havent installed them yet but here are some pics of the process.

PS- i added silicone caulk to the lights this time before re-baking them together. i had condensation issues with the LH lamp last wk, so am also duct-taping the edge of the whole assembly to keep it watertight.

LEDs on

11/14/12

i'm not familiar with the cree's. these were a pretty good deal.

http://www.ebay.com/itm/120990864899...84.m1497.l2649

in terms of heat sinking, the LED has a metal rim, backing and screw behind it - the metal also serving as the heat sink.

i have had them on for 15-minutes or so inside my house and they are still cold to the touch.

the LEDs were kindof tricky to attach to the projector beam housing. i used clear 3M trim adhesive (a little grey tube) and electrical tape.

1- dab of glue on plastic projector housing

2- stick the LED back piece to the projector housing

3- electrical tape over the work to keep it tight while drying and allow for proper alignment

4- repeat on other corners of projector housing, making a square shape and perfecting placement during glue curing time

11/14/12

due to unexpected interest in the lights, i went outside to take some installed pics.

some night time pics. had to pull out the DSLR bc iPhone cannot really do photos

the sky's the limit in terms of design options. the 3W LED dots are really affordable - $12 for a four-pack is pretty good. shipping takes a while. link below

4x White 3W LED DRL Eagle Eye Car Motorcycle Daytime Running Tail Backup Light

http://www.ebay.com/itm/4x-White-3W-...20990938897%26

this one shows the

- Rigid Industries Dually 2x2 highbeam

- Kensun 6000k HID lowbeam

- Quad 3W white LED points circling projector ball

11/17/12

hey guys,

i snapped some pics this afternoon of the quad LED points setup as a DRL.

they look pretty unique in this formation, and a guy in Lincoln Park drove up to ask if the LGT was for sale..!

opinions?

subaru or fuji heavy needs a German technical design R&D center pronto. m3s are hitting 186mph from factory and our pigs barely nudge 150mph

11/30/12

Well, here is a post about the LED Subaru Emblem DIY

it is a very simple and cheap mod that can be added to any car. to create an LED Subaru badge:

Supplies:

- LED badge

- 3M heavy duty outdoor double stick foam tape

- box-cutter or thin razor

- electrical tape

- wire clippers

Steps:

- determine if your badges are smaller Subaru ones, or big 4" ones on 08+ models.

- google shop "LED subaru badge"

- order one for about $15 from china. use paypal.

- await arrival (2 weeks)

- when arrives, bring to your car with a box-cutter or other razor. prod the OEM badge from the grille gently. it is double-stick taped, so more cuts and jabs of the blade will help it come off

- Unstick the back of the LED badge thing