Lightforce HID conversion (w/ Pics)

[slosurfer]

Finally I was able to get some pics tonight. There are a bunch so that you can have some comparison with my stock lights.

This wall was about 40 ft. away, and the camera was on the same setting and shot through the windshield. The last comparison shot was taken from outside the vehicle due to the hood being up to hook up the other 170.

Low Beams:


High Beams:


170 HID's Spot: (I have adjusted these away from each other since I took these pics)


High Beams and 170's:


170's with "clear combo" filters:


170 35watt HID on left vs. 170 100watt halogen on right:

[slosurfer]

Here are some comparison shots, same camera setting taken through the windshield, and I tried to replicate my recent shots with those taken about a month ago.

Two 170's spot with 100watt halogens:

Two 170's spot with 35watt HIDs:


Two 170's with "yellow combo" filters and 100watt halogens:

Two 170's with "yellow combo" filters and 35watt HIDs:

[Seanz0rz]

im sold!

[slosurfer]

Same spot as above but these are ones that I don't have "before" shots for. These pics are just because:

Clear combo filters:


High beams and combo filters:


Spots 50yds away:


Spots 100yds away:

[slosurfer]

Here's the writeup, I tried to make it a wiki but I couldn't figure it out and lost it. I'll try it again later. Let me know what you think.

Overview:

I really like my Lightforce 170's, they work very well as many of you know. I have been thinking of adding more lights, but I was worried about the added strain on my charging system. I started looking at HID's after seeing BruceTS's writeup on adding them to his Hella 4000's. I started researching and found that it was not going to be a "plug and play" event to add them to my 170's, but there seemed to be enough info that I was willing to take a shot at it. The idea of more light while asking less of my charging system was too much for me to pass up. This writeup will cover what is needed to retrofit the lights, not the actual installation of the rest of the HID conversion kit.

I should also say that this writeup should also work for the 240 Blitz lights as they use the same housing.

Required Materials:

Parts:

* Lightforce 170 Strikers or 240 Blitz
* 35watt H3 HID conversion kit
* 4 #8 screws (32 thread count) 3/8" long
* 4 #8 lock washers

Tools/Supplies:

* Nitrile Gloves (or something similar)
* Dremel and bit for removing aluminum material
* Cordless Drill
* 1/8" drill bit
* #8 32NC Drill and Tap set
* Rivet Gun and rivets
* 3/4" grommet with membrane (or other means to seal the rear of the housings)
* Lubricant for drill and tap and dremel bit
* Wire cutters
* Screwdrivers (for prying rivets and depending on what #8 screws you have)
* Vice press (optional but very useful for holding the heatsink while you work on it)
* 3/4" hole saw
* Optional- some kind of sealer to seal up the rear of the housing. I used Lexel and a caulking gun

Obligatory Disclaimer:

I am providing this write up for illustrative purposes only. Perform at your own risk. Any mods (including this one) you perform on your lights is your responsibility. These lights are not cheap, so take that into consideration. You’ve been warned.

Procedure: *Do not touch the HID bulb during this process!*

Step 1. Remove filter, lense, and bulb.

Remove filter and lense by turning the lense counterclockwise till it comes off the housing, being careful to not break the bulb when it comes off the housing.



Remove bulb by grasping the base of the bulb and pulling straight out.



Step 2: Remove heatsink from housing.

Using wire cutters clip the connectors off the wires coming out the rear of the housing so that they can be pulled through when you pull the heatsink out.
Using the 1/8" drill bit, drill out the rivet on the side of the housing that holds the aluminum heatsink. Once the rivet is out, remove the heatsink from the housing.



Step 3: Remove the bulb housing from the heatsink.

Drill out the two rivets that hold the bulb housing in the heatsink and remove the bulb housing from the heatsink.



Step 4: Mark heatsink to fit H3 bulb

Place heatsink back into housing, making sure to line the rivet hole up with the hole in the housing. Now mark the center line top and bottom on the front of the heatsink.



Measure the rear of the H3 bulb assembly to see how much material you will have to remove from the heatsink for the bulb to be placed from the front of the heatsink. Now mark where you will have to remove material on the heatsink (remember, it is safer to be on the small side so that you do not remove too much material)

See the pic below in the "drill and tap" step to see what material I removed.

Step 5: Clearance heatsink to fit H3 bulb assembly.

Using the dremel remove material from the heatsink, till you are able to get the bulb assembly flat against the heatsink. Mine only needed a little off the middle top and then a little more on the bottom middle.



Step 6: Drill and tap holes for the set screws.

Once the bulb assembly is flat against the heatsink, mark where the two screws will go that will hold it to the heatsink. Make sure it is not too close to either of the edges, so you don't drill through a side.

Drill and tap the two holes.




Step 7: Drill hole in rear of housing.

Use 3/4" hole saw to drill a hole in the center of the rear of the housing.

Note: I used the 1" grommets that came with the HID kit so I drilled a 1" hole. Unfortunately, the inside of the housing is 1" in diameter so the grommet doesn't fit exactly right. This is why I suggest finding a 3/4" grommet.

Step 8: Reinstall heatsink in housing

Do not do this step with the bulb in the housing.

Place heatsink back into housing and line up the rivet holes.

Use the rivet gun to rivet the housing and heatsink together.

Step 9: Install Bulb

Feed the wires and connectors through the front of the heatsink and back out the rear of the housing.

Fit the bulb housing flat against the housing and use the screws to hold it in place. Remember that this is aluminum, so do not overtighten.

Make sure the grommet is in place in the rear of the housing, sealing it from water.



Step 10: Install lense and filter

Install the lense and filter by screwing it clockwise onto the housing, being careful to not damage the bulb.





Step 11: Hook up HID conversion kit and enjoy.

I suggest hooking everything up and testing to make sure everything works prior to actually permanently installing the ballasts, etc.... that way if something doesn't work, it is easier to figure out what is going on.

Step 12: Optional: Use Lexel to seal up the rear of the housing.

After making sure everything was working, I sealed up my grommets with Lexel and a caulking gun. Mainly because my grommets were not fitting correctly since the inside diameter of the housing was also 1".





Feel free to private message or email me with any comments, questions, or concerns.

[Seanz0rz]

ill deff be doing a HID swap to some cheapter halogen lights at some time.

[BruceTS]

ill deff be doing a HID swap to some cheapter halogen lights at some time.

From my post at TTORA, it seems they are getting good results with the Hella 500's, quite a simple conversion using the H3 kit and drilling a 1" hole. Very similar to how I did the 4000's.

[slosurfer]

ill deff be doing a HID swap to some cheapter halogen lights at some time.

From my post at TTORA, it seems they are getting good results with the Hella 500's, quite a simple conversion using the H3 kit and drilling a 1" hole. Very similar to how I did the 4000's.

Yes the other lights are definately easier to do the swap on. I would like to see more after pics over on the ttora thread for the 500's.

Anyone want to give me a set of 240XGT's to see if I could retrofit them. J/K I think it would basically be the same thing as far as modifying the heatsink and drilling a hole in the back.

[BruceTS]

I would like to see more after pics over on the ttora thread for the 500's.

this first pic is of my car port no lights:

http://i219.photobucket.com/albums/c...Picture070.jpg

these next to pics are of hte Hella 500's with the white/black shields on just to show you how bright these things are and how much ambient light they throw off with the covers on.

http://i219.photobucket.com/albums/c...Picture066.jpg

http://i219.photobucket.com/albums/c...Picture067.jpg


the next one is the street lights without the 500's on

http://i219.photobucket.com/albums/c...cture069-1.jpg

and with them on of course I still have to adjust the beams right now they are set to about four house's away

http://i219.photobucket.com/albums/c...Picture068.jpg

[slosurfer]

Bruce, thanks I must have missed that one when I was looking through there the other day.