Headlight conversion 7” round (2 Viewers)

[Dissent]

Normally sandblasting before powder will prep it very well. Other than some stubborn slag, it turns out nicely after my final 120 grit that I finish them with. Although, if you were using auto paint, then you would need to prep more. Be careful that the wire didn't dig in and cause deep scratches or gouges because those are quite aggressive. Hit the faces with some 180 grit on an orbital or palm sander before powder.

I'm excited to see those crazy honeycomb lights!

Very true. There were some interior edges I wanted to round off on the back side and ended up doing most of them in case I want to bolt anything else down, run any wires, lights, etc. beyond the HID ballasts. I usually do the same prep on any metal fab projects because I'm never sure if I'll paint or powder coat them and I was on the fence for awhile on this one but settled on textured black powder.

I'll freshen up the face with some 180 grit before dropping it off. Thanks!

 

[kelly saad]

Very true. There were some interior edges I wanted to round off on the back side and ended up doing most of them in case I want to bolt anything else down, run any wires, lights, etc. beyond the HID ballasts. I usually do the same prep on any metal fab projects because I'm never sure if I'll paint or powder coat them and I was on the fence for awhile on this one but settled on textured black powder.

I'll freshen up the face with some 180 grit before dropping it off. Thanks!

Did you get the stuff I mailed?

 

[Dissent]

Did you get the stuff I mailed?

Yes, thank you. It arrived Saturday and I had those tabs welded on yesterday. Sorry for not responding quicker, it's been a very busy weekend! Thank you for the variety of tabs as well, that will really help with the 2nd headlight mounts.

 

[Dissent]

So I put together a the relay setup I am using. I used 2 relays behind each headlight and you could do it with one. I just did not want to run new wires over to make it work with one. Everything you need is there so why not use it. So now to pictures and how to wire it up

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I will give the relay pins to factory wire colors. In case your relay and pigtails are different. Just a warning the pigtails from hella have little numbers on each wire that do not match with the relay so ignore those.

Relay pin 87(5) power output to high beams 12v

Relay pin 30(3) and 85(2) will be wired together into the factory harness red/blue wire left high beam or red/white for right high beam theses are 12v

Relay pin 86(1) wired to the factory harness red/yellow wire on both side this will be the ground control for the relay.

I always check everything with a power probe and verify voltages and grounds. I do not know if the wire colors changes over the years but this is what I did for my 1997. I hope this makes it easy.

This does not apply at all to 100 series.

I'm getting ready to wire mine up and I'm using the same Hella relay and harness. I want 12v direct from the battery to the new lights so wouldn't Relay pin 30(3) go directly to a fused 12v battery connection? I don't understand why 30(3) and 85(2) would be tied together. Wouldn't this just activate the relay using OEM wires and then use the same OEM wires as a power source for the new lights? Is this config used to avoid altering the OEM harness and connectors in your case? in my case, I'm using 900x to H4/H1 adapter harnesses but I just want to trigger using OEM and then supply fresh 12v directly from the (fused) battery source.

 

[Dissent]

Got my LCG back from powder coat last week. Semi gloss black to match the BOR tube bumper.

For the 7" headlight I went with Dapper Lighting V2 HID.

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Fit and finish are great. Thanks for the outstanding work, Kelly.

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I still need to adjust the lights. ~ -5f at the time so "good enough" worked.

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I have Dapper Lighting HIDs, did you use the OEM wires and supplied H4 harness or did you integrate a relay in yours also?

 

[landspeed]

I have Dapper Lighting HIDs, did you use the OEM wires and supplied H4 harness or did you integrate a relay in yours also?

Yes, I spliced the supplied H4 to stock wiring. No need for the relay.

 

[Dissent]

Just finished running all the wires for the lights. I tapped off the drivers side high and low connectors, ran them through relays and ran wires across the radiator for the passenger side. Mounted the ballasts, connected to 2x fused sources then tested everything. Just waiting on the powder coated pickup on Tuesday to assemble it all.

 

[Dissent]

Back from powder coat. Black light texture turned out looking very good. With the flash the texture really stands out. Headlights mounted up and roughly aimed. Installing tomorrow night hopefully.

 

[voodu3]

@Dissent Those look awesome!

 

[kelly saad]

Those lights are sweet!

 

[Dissent]

Those lights are sweet!

Thanks. I dig the way they will match the larger honeycomb grille perfectly.

 

[auttiman]

I did not read the entire thread because my vacation is only for two weeks but I’m very interested in this mod for my ‘94....

How much $$$$ will the complete grill/headlamp parts cost?

 

[Clay LaGrone]

Pardon the crappy prototype, bare metal photos. Anyway, bleen working on this for a while now. I began several years ago but never finished it. I decided to dedicate more time to the headlights, and less time to grilles this month. Still making some adjustments to the prototype but it’s 95% good at this point.

These are built from 12 and 16 gauge steel, and are bolt-on replacement headlight assemblies for the 80 series Land Cruiser, also I built the 100 series lights too. These will hold any 7” round bulb style, or at least most. Light projection test showed very very minimal interruption of the light beam due to the depth of the bucket. I will include a pigtail for typical bulb styles, or a pigtail that could be connected to so the vehicles wires don’t need to be cut. These conversions work with the factory turn signals. There is another version that will be designed to fit against one of my grilles that will have a straight line instead of the original look of wrapping the headlights. These headlights will work with the factory grille too. Also, I’m designing removable rock chip guards for the extended off road adventures.View attachment 1622260View attachment 1622261View attachment 1622262

Without reading 20 pages of comments, what do they run and how quick can you deliver?

 

[clx16]

@Dissent Don't mean to rush you but.... you implied a legally binding contract to install and post pictures to the rest of us haha.

 

[FJRanger]

Without reading 20 pages of comments, what do they run and how quick can you deliver?

Go to Kelly's website for the prices, it's linked in his signature. There is a lead of a few weeks, as he does them in small batches. You won't be disappointed in the craftsmanship. If I hadn't put in DEPOs and hours into the wiring I would've gone with the round headlights in addition to the grill.

 

[Dissent]

@Dissent Don't mean to rush you but.... you implied a legally binding contract to install and post pictures to the rest of us haha.

LOl, I finished the install last night but got to bed late, I'll post up some pics later today.

 

[kelly saad]

Without reading 20 pages of comments, what do they run and how quick can you deliver?

I did not read the entire thread because my vacation is only for two weeks but I’m very interested in this mod for my ‘94....

How much $$$$ will the complete grill/headlamp parts cost?

Sent you both PM’s

 

[Dissent]

Heres some pics. My countertop aiming was pretty good, just a couple inches low and the drivers light was pointed in a bit. the beam cutoff is amazing but my passenger bulb looks whiter than my drivers. Going to follow up with a meter and Amazon about that. I have a lot of white light up front. The headlights have a 3x LED setup that is mainly for a DRL, I have it wired with the headlights now because I usually run headlights on. May change them to switched with key. Love the clear marker lights with switchback bulbs. Awaiting my valance clear lenses from Kazakstan next month. :/

Grille wise, I just had to play with the spacer washers a bit and Kelly's slotted mounting tabs made that very easy to stack 5x on a single bolt and not drop any. Thank you!
My marker lights gave me some fits but I have an early model of the grille and headlight buckets that was more product display than final product so that won't be a normal experience for you guys.
My truck looks pretty neat lit up at night, I have so much white light now! I powered on my HIR bulb and they look like a 1987 Mag flash light compared to my 35w HIDs. I used an existing bolt along with some spacers and a sheet metal screw to mount then behind the marker. I am very happy with the result and am looking forward to my final grille insert cutout for 2x 6-7" additional lights.

If anyone is looking for an awesome powder coater in Phoenix, call Brian Caudron at AZ Custom Coatings (480) 201-7279 in Tempe off Kyrene and Baseline. He's done all my powder work and is very reasonable and very fast. He was very impressed with the craftsmanship of this unit.
Awesome work Kelly and amazing customer service. You sir are a fabricator now, no doubt about it!

 

[Dissent]

Some more pics about how I mounted the HID ballasts.

 

[kelly saad]

It’s so nice to see the road at night!