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How To: Legal Headlight Upgrade

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142K views 246 replies 92 participants last post by  New2diesel2003  
#1 · (Edited)
Following input several months back from ‘Reids Marine’, today I did this headlight upgrade and took some pics to share.

When complete, we will increase the low beam’s output by 85% to 1,850 lumens and the high beam’s output by 36% to 2,300 lumens.

These high-intensity bulbs are the same dimensions and focal point as the OEM bulbs with only a small alteration needed to fit. This is a Legal upgrade for your OBS headlights (not illegal HID retrofits) and maintains the same 55w (low) and 65w (high) draws, requiring no wire harness upgrades.

Needed items;
2- Philips 9011 bulbs,
2- Philips 9012 bulbs,
Dremel style cut-off blade,
Razor knife blade,
And 1 Nickel

Open the hood, pull the pin, lift and pull the fixture out and leaving the bulbs in place, release the lock tab and pull the connectors. Now pull the bulbs and lay aside.

I used the cardboard box that Amazon shipped in and, using a nickel, traced the outline, twice, and cut out the 2 holes.

Insert the low beam (9006) bulb into the hole and making a template; trace the outline of the tabs as seen here:





Extend the cut lines on the template



Insert the new 9012 bulb in the hole so it’s protected. Holding the bulb in place, follow the template lines and with the dremel, cut down the center tab to match.



Insert and check fit;





Next, insert the high beam (9005) bulb into the 2nd hole, mark for your template, insert the new 9011 bulb and cut the center tab to match.


Image


Finished;





Repeat for the 2 bulbs on the other side, and you’re done.
This is a nice improvement that's whiter and extends further without blinding other drivers, goin’ Cyclops (or blind) in the middle of nowhere, and/or getting’ tickets. $85 ttl, to my door....give it a try. :thumb
 
#2 ·
Sounds awesome!


Sent from my Autoguide iPhone app
 
#8 · (Edited by Moderator)
Is this only for OBS trucks or will this work for the LML also? Sorry if this is a dumb Question.
 
#9 ·
^^You can do the same upgrade with the highs, bumping up to the 9011 bulb.
 
#10 ·
Thank you.
 
#12 · (Edited)
Update....

Just an update on this mod:

I’ve had a chance of late to run some night miles on a long stretch of moderately turning, wide lane divided highway, away from any city lights and with no road illumination.

Running with the driving/fog lights, the new bulbs now fill-in the gaps that were between the two sets. The added more brilliant white light is nice, but instead of the gradual fade of the footprint out deep, there’s now a definitive line of demarcation way out front.

Extended distance sight is what I was going for, not just a whiter light up close. With this particular stretch of highway, white reflective concrete instead of dark asphalt and no lighting, it gave me the perfect conditions to compare my headlight footprint with vehicles either passing on the left or being passed.

With the fronts lined up, my footprint was consistently ‘Out There’ over theirs. And, there were plenty of illegal HIDs running thru to compare also. The only vehicles that came close to matching my footprint were Halo fixtures, and then only the lower color levels could compete for distance sight.

The worst comparison was the ‘blue’ HID conversions. While they glowed obtrusively for the 1st 25’, their distance sight was only half of mine. No where near close in comparison.

These don’t blind oncoming traffic; in fact they look relatively the same coming at you. I installed one set only, then went out 70’ and took a pic (an hour away from dusk). There is no discernable difference with the naked eye when looking at the old and new bulbs, side by side.

Can you tell which one is new, left or right?

Lows


Highs


An interesting note: The optimum color level for the human eye to see the greatest distance at night is around 4300k. Once you get above that on your way towards 6000k, no matter how bright you ‘think’ they are, you’re actually diminishing your discernable distance sight.

“Mine aren’t blue, just a pure white.” No, they’re not. You’ve bumped up (6000k) towards the blue spectrum and the human eye will see a shorter distance with that color. I watched it occur time after time with the passing cars coming in from the Houston area.

While they were brighter than mine close in, the distance sight just didn’t measure up. It wasn’t even close.

The new high beam stretches out further too. Pull the lever back for a momentary ‘all on’ and it’s quite the show. :thumb
 
#14 ·
I put the 4300k HID on my motorcycle low beam. It was easily double the light output and pure white.. it puts off less heat than the halogen... and yes, it is BRIGHT. I don't get the "light flash" from folks... so, a good upgrade to consider...

I have approval from the police that this is an ok upgrade... but the higher temp ones like the 'blue' and violet ones are not legal.
 
#16 · (Edited)
The only source I found was Ebay and Amazon and only Philips in those numbers.

Just add 6 to the stock number.

Your truck uses 9006/low and 9005/high.
Upgrade numbers are 9012/9011.
 
#18 ·
hmm..might do this instead of HID's...seems more legit..lol
 
#19 ·
I've been looking for a sensible light upgrade. Before I got my 06 GMC Duramax, I had a half ton 06 Silverado (with the all-8 or whatever mod). My Silverado had great headlights on it. Lows were nice and bright; highs were like the sun. I'm a bit disappointed with my Duramax. I wonder if part of it was because of the clear lenses on the Silverado vs. the fluted lenses on the Sierra. I was considering replacing the fluted lenses with Denali projectors, or perhaps HID.

I want good clear light without blinding on-coming traffic, and far reaching highs with good reliability. (I.e.; no worries of ballasts not firing, etc.) My Silverado was perfect, with the exception of the occasional flash from other drivers while on low beams.

What is the difference between these bulbs and the regular 9006/9005s?
How do these compare to halogens in a projector (Denali) lens?
 
#20 ·
May have to get rid of my HID for these and new housing being mine are starting to look bad.

Yellowchevy
 
#25 ·
Why ??????:cookoo[1]:

Just change your HID bulbs to 4300K and they'll smoke this halogen upgrade in performance !!




.
 
#21 ·
so.... all on mod + this mod+ two 10" rigid spot lights and 1 rigid flood will probably be enough then? good work. Still not realy understanding hte extra step with the cardboard. couldn't you just sit there with a head light in your lap and go to town with a razor knife till it fits?
 
#22 ·
this sounds like a good upgrade how much in parts?
 
#23 · (Edited)
The cardboard was handy to 1. create a template of the old stock bulb to use to cut down the larger tabs on the newer bulbs to match, and 2. it protects the builb from any oils from your hands while handling and from any slip that may occur with the dremel cut-off wheel.

The prices ranged from $18 sumpthin' to $20 sumpthin, about $85 shipped for all 4.

I work on-call, 24-7, and the truck/trailer need to be ready to roll at any time and drive thru the night. I can't risk the gamble on an HID ballast meltdown while 200 miles from nowhere in the middle of West TX. So this was the way to go for me.

With an 85% increase in lumen output, I continually measure these against other night traffic's headlights as I overcome and pass them by. When the leading edge of my beams line up with theirs, my truck is still 2+ car lengths behind theirs.

As I do the same comparison against the blue/white HID conversions, theirs glow brighter for the 1st 25' out, then drop off substantially. Where these are still out beyond theirs. Without projector lenses, they're fighting a loosing battle with that light's color/freq, as it fades quickly with distance beyond that initial hot spot in front.

Since they're using the same housing and reflector as with the OEM bulbs and share the same lightwave characteristics, they don't blind oncoming traffic. Only you can see that they reach out farther.

The OEM brights were good, but these kick it up a few notches and stretch WAY on out there....oncoming traffic have no doubt that you've switched down to lows. I've only compared the brights to a Ram that I've passed. He seemed to be running both high and lows together, but as I passed and kicked up my highs, they were WAY out beyond his by at least 3x.

YellowChevy, mine too started to haze/yellow/fog. I used McGuire's Plastic restorer, an applicator pad and some elbow grease and they shined up well. $8, it's worth a try if they haven't turned too badly yet.
 
#26 ·
The cardboard was handy to 1. create a template of the old stock bulb to use to cut down the larger tabs on the newer bulbs to match, and 2. it protects the builb from any oils from your hands while handling and from any slip that may occur with the dremel cut-off wheel.

The prices ranged from $18 sumpthin' to $20 sumpthin, about $85 shipped for all 4.

I work on-call, 24-7, and the truck/trailer need to be ready to roll at any time and drive thru the night. I can't risk the gamble on an HID ballast meltdown while 200 miles from nowhere in the middle of West TX. So this was the way to go for me.

With an 85% increase in lumen output, I continually measure these against other night traffic's headlights as I overcome and pass them by. When the leading edge of my beams line up with theirs, my truck is still 2+ car lengths behind theirs.

As I do the same comparison against the blue/white HID conversions, theirs glow brighter for the 1st 25' out, then drop off substantially. Where these are still out beyond theirs. Without projector lenses, they're fighting a loosing battle with that light's color/freq, as it fades quickly with distance beyond that initial hot spot in front.

Since they're using the same housing and reflector as with the OEM bulbs and share the same lightwave characteristics, they don't blind oncoming traffic. Only you can see that they reach out farther.

The OEM brights were good, but these kick it up a few notches and stretch WAY on out there....oncoming traffic have no doubt that you've switched down to lows. I've only compared the brights to a Ram that I've passed. He seemed to be running both high and lows together, but as I passed and kicked up my highs, they were WAY out beyond his by at least 3x.

YellowChevy, mine too started to haze/yellow/fog. I used McGuire's Plastic restorer, an applicator pad and some elbow grease and they shined up well. $8, it's worth a try if they haven't turned to badly yet.


Compare to 4300K HID's and Halogen will lose miserably though...


/
 
#27 ·
Sub'd


Sent from a hand held key-lime pie
 
#29 ·