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  #1  
Old 04-01-2016, 11:06 PM
Yadkin Yadkin is offline
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Default Bi-Xenon headlight conversion

I found a set of four made by Delta Tech Industries in Ontario California. Amazon has them for under $200.

This is not a "plug and play" installation. You have to cut your headlight buckets, and the chassis metal behind them. You also have to buy two headlight connectors and make some minor wiring changes.

I used a dremel to cut the first two headlight buckets. The kit instructions say cut a 2-1/2" hole, but a 2-3/4" is what is needed. I didn't have a hole saw that size and didn't want to make a trip to Lowes, so I used a dremel cut off blade. A little bit of grinding then re-paint and you're done with this step.
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Old 04-01-2016, 11:08 PM
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Next use a hole saw and drill a 2-1/2" hole in the chassis metal behind the bucket. Here is the hole after cleaning and coating the bare steel with red primer.
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Old 04-01-2016, 11:10 PM
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Here's the low beam. It uses an H4 bulb. Note the complex lens pattern that arcs the beam down at the opposing traffic.
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Old 04-01-2016, 11:15 PM
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And the high beam. Simpler lens pattern.
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Old 04-01-2016, 11:18 PM
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The high beam uses the same 2-element H4 bulb, and the stock connector will only accept two prongs. And, since the bulbs are deeper, the low beam connector ends up accessible inside the fender, so you have to make the appropriate changes to the wiring harness.

For my harness I feed the high beam first then feed the low beam, the opposite of how the factory did it.
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Old 04-01-2016, 11:20 PM
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Here the drivers side has the conversion while the passenger still has the halogen sealed beams. The conversion looks blue, but it's actually closer to pure white. I'm guessing about 5000K.
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Old 04-01-2016, 11:22 PM
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Here is what it looks like down range with low beams only. Again only the drivers side has the conversion. Note the sharp cut-off compared to the sealed beams.
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Old 04-01-2016, 11:23 PM
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And high beams, down range.
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Old 04-01-2016, 11:29 PM
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I forgot to mention that his kit requires a relay pair mounted close to the lamps. I had already done that conversion. These draw more power than than the original bulbs and you don't want to put all that power through your headlight switch. The relays will also reduce voltage drop a huge amount, so the lights will be brighter.
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Old 04-02-2016, 01:47 AM
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Since the new lamps require more power to run and many more electrical accessories tempt us, the old generator is probably under powered and out the window. So is the old mechanical regulator.

Some guys gut the original regulator and mount two headlight relays inside, just to maintain the appearance of being 'stock'. It also makes a clean installation.

H4 lamps are great. I use them. They come in a variety of wattages but they also get very hot. More than ever, you need good grounding conductors. - Dave
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