cheap driving lights

[corax]

Everyone's seen those cheap utility lights mounted to the side of a semi or on a tractor, doing a bit of research I found out how to make one of these into a decently bright driving light just by swapping in a new sealed beam. This will provide a cheap, light weight and vibration resistant light to help me avoid all the deer just waiting to jump in front of me when I'm bombing down country roads at night.

The heart of this is this sealed beam, NAPA p/n LMP 4509 (~$15). It's listed as an aircraft spotlight beam, and is rated for 100W at 13V producing 110,000 candlepower - if you can get a full 14V down to them expect a bit more
http://i280.photobucket.com/albums/kk171/batardsalamano/cheap%20driving%20lights/100_2652.jpg

The rear of the 4509 bulb has screws to secure the wiring
http://i280.photobucket.com/albums/kk171/batardsalamano/cheap%20driving%20lights/100_2661.jpg

Here's the utility light I'll be using for this (Harbor Freight <$10)
http://i280.photobucket.com/albums/kk171/batardsalamano/cheap%20driving%20lights/100_2663.jpg

Start by getting the old light out of the rubber housing. Be careful not to chip the light when you pry it out by sliding a screwdriver as far behind it as possible. After you pop one out, you begin to realize that these lights will NOT fall out on their own going down the road.
http://i280.photobucket.com/albums/kk171/batardsalamano/cheap%20driving%20lights/100_2664.jpg

Here's the light taken apart (note that this one isn't a sealed beam, but uses a regular H3 bulb).
http://i280.photobucket.com/albums/kk171/batardsalamano/cheap%20driving%20lights/100_2665.jpg

Snip off the black ground wire going to the rivet on the inside, it doesn't provide a good ground and will eventually will fail causing the light to go out.
http://i280.photobucket.com/albums/kk171/batardsalamano/cheap%20driving%20lights/100_2666.jpg

Here's the new bulb wired and ready to be popped back into the housing. I used 14 gauge wire to connect to my pre-existing light harness which uses 12 gauge from a 40 amp relay. The black ground wire goes to the mounting bolt into the 'runner's frame
http://i280.photobucket.com/albums/kk171/batardsalamano/cheap%20driving%20lights/100_2667.jpg

It even says "AIRCRAFT" on the back of the bulb
http://i280.photobucket.com/albums/kk171/batardsalamano/cheap%20driving%20lights/100_2669.jpg

Mounted up with a simple 90 degree bracket to the bolt hole on top of the frame just inside of the body mounts
http://i280.photobucket.com/albums/kk171/batardsalamano/cheap%20driving%20lights/100_2672.jpg

All finished
http://i280.photobucket.com/albums/kk171/batardsalamano/cheap%20driving%20lights/100_2674.jpg
http://i280.photobucket.com/albums/kk171/batardsalamano/cheap%20driving%20lights/100_2675.jpg

I'll get beam pattern shots later when it gets dark, but I can already tell they throw a ton of light. Standing 15' away on a 40 degree day I can feel the heat from the light on my hand . . .

[4x4mike]

Those look crazy bright. Is there any chance of melting the rubber housing using the new light?

[04 Rocko Taco]

I was going to say, that while a really cool trick, it looks like your new aircraft lights are going to melt your cheap harbor frieght housings. :)

[oly884]

Very nice, I did a similar setup a LONG time ago. For the money, they are a great way to put some extra lighting down range while on a budget.

[corax]

I was going to say, that while a really cool trick, it looks like your new aircraft lights are going to melt your cheap harbor frieght housings. :)


I don't think it'll really affect it that much, remember rubber doesn't really melt (it does burn, but not at the temps these will see). Anyway, night time shots and heat testing will have to wait until I get back . . .

[YotaFun]

better watch the regulations here in PA
so far my little "Subaru" fog mod seems to be passing the cops without issues,
granted i have it so when the high beam indicator on teh dash lights up,
the lights i have come on too.

looks good dude!

[paddlenbike]

Man, you're killing us! Two nights with no beamshots? :D
:pics:

[corax]

better watch the regulations here in PA
so far my little "Subaru" fog mod seems to be passing the cops without issues,
granted i have it so when the high beam indicator on teh dash lights up,
the lights i have come on too.

looks good dude!


As far as cops go, I think a big part of it has to do with the size of the lights and how far off the road they are. Best bet is to make them not so obvious so the police don't give them a second look.



Man, you're killing us! Two nights with no beamshots? :D
:pics:


I'm in a hotel in Philly with my dog in U of Penn Veterinary Hospital, about 2.5 hours from home . . . when I get back I'll be sure to snap a pic. I did light them up in the driveway and can say they throw a lot of light, but it wasn't a good shot to show distance or beam spread

[YotaFun]

I'm in a hotel in Philly with my dog in U of Penn Veterinary Hospital, about 2.5 hours from home . . . when I get back I'll be sure to snap a pic. I did light them up in the driveway and can say they throw a lot of light, but it wasn't a good shot to show distance or beam spread


how long are you folks planning to be up there?

[corax]

from these you can see that the headlights don't even compare to the spotlights . . . in fact, I could hardly tell when the headlights were on except the headlights have a wider beam and filled in the sides a bit

low beam headlights
http://i280.photobucket.com/albums/kk171/batardsalamano/cheap%20driving%20lights/100_26801.jpg

spot lights only (ignore the poor aiming on the right side, I need to modify my mount a bit to get it up a bit)
http://i280.photobucket.com/albums/kk171/batardsalamano/cheap%20driving%20lights/100_26811.jpg

low beams + spots
http://i280.photobucket.com/albums/kk171/batardsalamano/cheap%20driving%20lights/100_26821.jpg

high beams + spots
http://i280.photobucket.com/albums/kk171/batardsalamano/cheap%20driving%20lights/100_26831.jpg

[slosurfer]

Sweet!!!! :thumbup:

[Tankota]

I just got my harbor freight sale flyer the other day. I saw those lights for like 7.99. Think I might get a couple for switchable reverse lamps.
One thing, do they wiggle on their mounts at all? I had a pair of HF "off road" lights on my bumper for a while and the would vibrate up and down alot. It kinda drove me crazy.

[4x4mike]

Wow, those are some throwers. Good luck on getting that side up.

[corax]

I just got my harbor freight sale flyer the other day. I saw those lights for like 7.99. Think I might get a couple for switchable reverse lamps.


That'd be some sweet revenge on tailgaters and dorks that can't flip their high beams off when they're behind you . . .



One thing, do they wiggle on their mounts at all? I had a pair of HF "off road" lights on my bumper for a while and the would vibrate up and down alot. It kinda drove me crazy.


As long as the mount itself is solid, you should have no problems - the rubber itself is decently thick and inflexible where the metal is riveted on. I didn't drive with them on at night yet, but I did during the day (on a rough back road) and they looked pretty steady (even in direct sunlight I could see where the beam was hitting the ground). I'll let you know after I do some extended night driving (in a day or two).

[corax]

One thing, do they wiggle on their mounts at all? I had a pair of HF "off road" lights on my bumper for a while and the would vibrate up and down alot. It kinda drove me crazy.


I had them on for a good 15 minute stretch tonight, no wiggle or bounce at all - I think it all comes down to rigid mounting (these weight practically nothing anyway). One other thing, these definately have a tight beam spread. I may get a third one to point straight ahead and aim the other two a bit more to the outside

[Tankota]

Well thats good to hear.
Being aircraft lights I'm sure their designed with a really tight beam as you said. But that can be nice for long range lighting. Thats what you need if your driving at speed.

[corax]

*update*

I've had them on for a few months (< 10 hours use) and have them wired to come on with the high beams (headlights need some work), the tight beam pattern is great for long distance while what little light the headlights put out is good for side filler up close. I don't even want to drive backroads now without these on, it's a world of difference. I would probably compare them to the 6" 100W Hella "KC daylighter look-alikes" I had on my last truck.

No problems with the housings even though the lights do get toasty hot (you can feel the heat from the beams just by standing 5 feet in front of them, even in sub-freezing weather) - longest I've had them on for at one time was ~1 hour with no problem - very steady beams while driving too.

on a side note, I haven't been hassled by the PA cops either, partially, I think, because they're not mounted on the bumper and don't look as bright as they are.

[corax]

*update*

8 months and going strong, I like these better than the 100W Hellas I had on my last Toyota (stealthier for sure) . . . no issues with the rubber housing, no issues with law enforcement or state inspection. The longest I had them on at any one stretch was ~1 hour, but they get to temp in a few minutes so I imagine longer periods wouldn't have any adverse effects. Beam pattern is stable at speed over washboard, but that's really a function of secure/stable mounting as the housing itself is lightweight.

[CJM]

Beam is would you say quite narrow?

[corax]

they are tight and designed for distance, the high beams just fill in the sides a bit. I have them aimed slightly to the sides and feel confident taking corn field lined back roads at ungodly speeds on a moonless night

[CJM]

Sounds good, light have to slap some on after I do the HID conversion to my KC 5x7's.

[YotaFun]

Keith you should install these in those lights
http://www.ddmtuning.com/index.php?p=product&id=102&parent=85

[corax]

not sure how I could? - the original "utility" bulb used a removable H3 bulb, the Spot pattern is a sealed beam.

http://i280.photobucket.com/albums/kk171/batardsalamano/cheap%20driving%20lights/100_2661.jpg

[YotaFun]

You said a removable H3 right?
I think that site has a HID kit for each bulb type