Here I am

AlphaREX NOVA headlights

Attention: TDR Forum Junkies
To the point: Click this link and check out the Front Page News story(ies) where we are tracking the introduction of the 2025 Ram HD trucks.

Thanks, TDR Staff

Pause on low to high beam with LED headlights

How to I test Alternator output to my batteries

Status
Not open for further replies.
I bought my truck in 2018. Right before I got it, the owner (who had it several months, but was a flipper, usually of sports cars) had replaced the headlights with aftermarket. A year or so later I grew tired of the headlights shining in the trees, up in the sky, everywhere but on the road, and the half dome reflectors over the parking/turn lamps had MELTED onto the bulbs. I had the dealer give me a biz to biz print out of dealers with OEM stock of the lights (by P/N ), bought and installed them new (rather pricey, about $400 each) They worked well, but I still pondered what to do. I considered some new, high powered lamps but realized the reflectors were not suited for a sharp upper cut off of the light that I needed to keep from blinding other cars.

After watching a number of videos, most notably the Just Diesels series on headlights, I realized that the NOVA light were the ones I wanted.

End result was a Christmas present to my truck of a set of the Chrome version of the NOVA lights. (grill and bumper and bug deflector are all chrome, the chrome lights were cheaper and matched well).

For some reason, on the first installation of the earlier lights, I had not noticed how crooked the front bumper was. This was from the factory, no washer shadows where they have been loosened and moved. The drivers side was too close to get in easily and remove the lower outboard bolt. I ended up loosening the LH bumper bolts and lowering the bumper to get within the manual spec for bumper to fender gap of 19mm +/- 3mm.

I removed the LH wheel well plastic shroud (8 screws, easy to remove) and it helped considerably in routing wiring for the daytime running light module. The lights worked without the DRL but I paid a lot of money, so why not? The electronic module I mounted on the outboard side of the battery box and I covered all wiring in split wire loom.

I didn't like running the single wire straight across to the right side for the DRL so I spliced in more red 18 ga primary wire using weatherproof Ray Chem butt splices. I traced the wire along the inside of the bottom of the bumper with the fog light wiring and ty-wrapped to it.

I have driven it several times at night, playing with the up/down adjustments to get the cut off line so it hits cars about the top of the hood or trunk and no higher when 5 to 8 car lengths away. lots of light far away on open road that way.

I will post pics eventually, don't have any now, it went and got cold on us:(:eek:

Two things I noted. L/R adjustments looked good out of the box, vertical adjustment not too bad but needed some adjustment. The L/R adjustment screws are totally inaccessible without removing the lights. Even with the wheel well shrouds out, there is fender metal blocking getting anything on them as they are only a quarter inch or so from the fender structure. The vertical adjustments are accessible without removing the lights. I used a 4 mm hex socket (which is what is called for in the instructions) and a very short ratcheting bit holder with a square drive. The drivers side, I can easily reach from above sticking my arm thru an opening inboard and above the lights, with the hood open. The right light requires laying beneath the truck and reaching way up and feeling around to find the adjuster and getting the socket on it. I have done this multiple times, and its not too hard....... if you don't have King Charles' "sausage fingers" as he himself described them recently, and your arms are not too fat.

Main complaint is that the amber prismatic reflector inside the light DOES NOT REFLECT AT ALL. I have repeatedly shined my bright LED flashlight on it directly from the side, 50 to 75 feet away, and get no reflection what-so-ever. This led me to install https://www.grote.com/signal-lighting/reflectors/stick-on-tape-reflectors/41143/ made from a DOT tape (USA Made and very highly reflective) on the upper aft corner of the bumpers. I have similar red reflectors on the back bumper, though the taillight reflectors are the best I have ever seen on a vehicle. I am a huge fan of being visible.

Pics, shop door open, shining on trees 75 ft away, new vs old headlight. The tool is a ratcheting bit holder with a square drive, and a 4mm socket on it. lights shining on the door with ribs on it makes it easy to adjust the headlights up or down in small amounts and keep them even.

Charles
initial comparison of new left and old right headlight.jpg four mm socket and bit holder for headlight adjstment.jpginside of door make it easy to see the lights move when adjusting them.jpg
 
Last edited:
Main complaint is that the amber prismatic reflector inside the light DOES NOT REFLECT AT ALL. I have repeatedly shined my bright LED flashlight on it directly from the side, 50 to 75 feet away, and get no reflection what-so-ever. This led me to install https://www.grote.com/signal-lighting/reflectors/stick-on-tape-reflectors/41143/ made from a DOT tape (USA Made and very highly reflective) on the upper aft corner of the bumpers. I have similar red reflectors on the back bumper, though the taillight reflectors are the best I have ever seen on a vehicle. I am a huge fan of being visible.

This is what made me add 6 sets of 3, 3/4" LED high/low lights on my running boards! All 3 come on with the marker lights, the middle is on during the day with DRL (front turn signal) and center flashes with turn signals. Have an LED driver that will flash the 1st and last at different times when on shoulder or as needed. LED driver has 6 channels with 10 amp capacity and over 20 patterns. Yes, Ill look like a Christmas tree with them on! But that's what I want. Will be adding other 4 channels front and rear this spring to give better 360 degree visibility.

@CharlesinGA, Glad you took the time for the run down on the lights. I'm sure that it will help someone that might be on the fence about them.
 
Being visible........... I added DOT reflective tape to the back of my travel trailer. The typical 4x4 thin steel tube bumper has an extruded aluminum trim cover on it, a vinyl strip down the middle and no slip ribs on top. There are two smooth one inch wide strips on it, so I bought one inch DOT tape and applied it all the way across, so that red was outermost.

When I installed the white LED backup light in the place of the original that had red prismatic reflector surrounding the white lens, I also added plastic reflector strips under the lights. I have longer ones I plan to install eventually.

One issue I am encountering is the number of inline fuse feeds tapped off the battery. I first put in the intank fuel pump conversion so that added one, then the PacBrake added one for the air compressor, and now the DRL installation adds another. I'm trying to figure out where to install a Blue Sea 6 position fuse panel with a cover. Lots of room on the right side but nothing on the Left. The DRL module and wiring can be reversed to put it on the right, but the fuel pump and the air compressor would require long wiring runs from fuses on the right, over to the left. I will do that if I install a larger compressor on the RH frame rail, then the compressor fuse will get moved to the right, the DRL can be moved, and the fuel pump is one wire to run across in the upper firewall conduit. Time consuming but doable if I put a compressor on the frame and get the existing one off the engine.

Warmer tomorrow, will try to get some pics.

Charles

Tail light with final DOT tape install and Grote prismatic reflector added.jpg
 
Last edited:
Being visible........... I added DOT reflective tape to the back of my travel trailer. The typical 4x4 thin steel tube bumper has an extruded aluminum trim cover on it, a vinyl strip down the middle and no slip ribs on top. There are two smooth one inch wide strips on it, so I bought one inch DOT tape and applied it all the way across, so that red was outermost.

When I installed the white LED backup light in the place of the original that had red prismatic reflector surrounding the white lens, I also added plastic reflector strips under the lights. I have longer ones I plan to install eventually.

One issue I am encountering is the number of inline fuse feeds tapped off the battery. I first put in the intank fuel pump conversion so that added one, then the PacBrake added one for the air compressor, and now the DRL installation adds another. I'm trying to figure out where to install a Blue Sea 6 position fuse panel with a cover. Lots of room on the right side but nothing on the Left. The DRL module and wiring can be reversed to put it on the right, but the fuel pump and the air compressor would require long wiring runs from fuses on the right, over to the left. I will do that if I install a larger compressor on the RH frame rail, then the compressor fuse will get moved to the right, the DRL can be moved, and the fuel pump is one wire to run across in the upper firewall conduit. Time consuming but doable if I put a compressor on the frame and get the existing one off the engine.

Warmer tomorrow, will try to get some pics.

Charles

View attachment 139598


Do the upper as well.

https://dotsafetytape.com/wp-content/uploads/2020/05/Screen-Shot-2020-05-30-at-12.07.21-PM.png
 
Adding a few pics here. The truck is outside in the dark, possibly a little light coming from behind thru the shop door. I took the original Daimler Chrysler headlight and set it below the truck at the appropriate angle. You can see that it, and the Grote reflective dot on the bumper reflect the flash fine, the reflector in the NOVA light does nothing, and its the same with a bright flashlight on it.

Disappointing to pay a grand for lights, and have something as simple as a prismatic reflector not work. How does one mess that up.

I also did one of the rear, to show how well the OEM taillights reflect and also the red Grote reflector dot.

One shot of it installed, you can get better images on the website. The light is off, the three low beams are merely reflecting the camera light.

One other thing I forgot to mention is that when you open either door, it wakes up the computer and the truck spikes the lighting for a split second with power, probably to determine if a bulb is out. The LED lights are so fast to respond that they actually flash while a regular light does nothing. I drove it quite a few miles tonight, some in traffic and some on open country road. The lights work well, may need tweaking up very slightly.

Charles
front side reflectors RAM.jpg rear reflectors on RAM.jpg front light assembly RAM.jpg
 
That light wouldn't pass the muster without the reflector not doing what it's supposed to do. Meaning that it couldn't have been certified as a replacement light. Looked on their site and didn't see a certification listed. Just have to weigh the good and bad with so many lawyers out there today! Just because they sell it, doesn't mean that it's "road" legal, with many places saying off road use only to get away with selling products.
 
That light wouldn't pass the muster without the reflector not doing what it's supposed to do. Meaning that it couldn't have been certified as a replacement light. Looked on their site and didn't see a certification listed. Just have to weigh the good and bad with so many lawyers out there today! Just because they sell it, doesn't mean that it's "road" legal, with many places saying off road use only to get away with selling products.

I looked at the web site and found this......... We design our lights from inception, patent every component we’ve designed, and guarantee that our products are compliant with the SAE and DOT requirements. Our products are also certified to ISO-9000, ISO-9001 and ISO-9002 standards.

I sent an email to them and finally received a response. About the reflector they claim that that is an amber LENS and not intended to be a reflector.......... not what I was expecting but I had sent them the pic I posted of the nighttime pic of the OEM light on the ground reflecting away and the Grote reflector on the bumper also reflecting away and the non reflecting "amber lens" . I'm not real worried about it, possibly they will improve them eventually. I did mention that even my 1970 Mustang had sidelights with reflectors that worked.

As for the DOT certification, they did send me a pic of where that is found on the light, which I will post here. Its right along the bottom in the inboard curved section, I refer to these lights as the "sad eye lights". Mine are difficult to see but the markings are there.

As to the terminals on the wires for the DRL module not being large enough for the battery clamp bolts, they said that it was a module used on many of their kits and battery bolt sizes vary. This is no wholly true as they do customize the fuse box tap for this installation, so they could customize the terminals for the battery also. I did suggest they provide larger terminals for the installer to use since they were aware that the ones on the wires were not large enough for all installations.

All in all I'm quite happy with the lights, just disappointed by some small details that should have been ironed out a long time ago.

Charles

Alpha Rex NOVA headlight DOT approval.jpg
 
Last edited:
The ISO numbers mean nothing more than a factory standard. The DOT # can be faked and if the OEM has a reflector and this replacement doesn't leads me to believe that it doesn't have a DOT# other then maybe the plastic it is made of is of a DOT rating. All vehicles on the road are required to have that reflector built into the lamp for safety. You could not have working lights on that side and could lead to an accident. Why have to add something to bumper to correct something that is supposed to have it to be legal on the roads. Glad they're working for you, wouldn't waste my money on them to have that! If I ordered and found that, they be going back for full refund and they would be paying for return shipping! JM2C.
 
Backing up Topzide here, assuming the subject AlphaREX headlamps were manufactured on or after 1/11/2017, the documentation for why the replacement headlamps would not be DOT compliant is as follows:

The 2002 version of the relevant rule (49 C.F.R. §571.108) (i.e., the rule that applies to CharlesinGA's truck) requires side marker lamps AND reflex reflectors "On each side...1 amber as far to the front as practicable." (See Table III and Table IV.)

Every recent version of the relevant rule since at least 1/11/2017 (current version went into effect three days ago, 02/01/2024) that I could find includes the following language:

S6.7.2 Version of this standard. The requirements of S6.7.1 must be met, at the option of the manufacturer, using either the current version of this standard or the standard in effect at the time of manufacture of the original equipment being replaced.​

This means that regardless of whether the manufacturer wishes to comply with the standard in effect for required lamps and reflective devices at the time that CharlesinGA's truck was made, or with the standards that were in effect at the time the replacement headlamps were made, the replacement headlamps MUST comply with S6.7.1, even though there is no requirement corresponding to S6.7.1 in the 2002 standard. OK, so what does the 2017 version S6.7.1 say?

S6.7 Replacement equipment.

S6.7.1 General.
S6.7.1.1 Each replacement lamp, reflective device, or item of associated equipment, including a combination lamp, must:
(a) Be designed to conform to meet all requirements specified in this standard for that type of lamp, reflective device, or other item of equipment (in the case of a combination lamp, it must meet these requirements for each function); and
(b) Include all of the functions of the lamp, reflective device, or item of associated equipment, including a combination lamp, it is designed to replace or is capable of replacing (other than functions not required by this standard).​
S6.7.1.2 Each replacement lamp, reflective device, or item of associated equipment, including a combination lamp, which is designed or recommended for particular vehicle models must be designed so that it does not take the vehicle out of compliance with this standard when the individual device is installed on the vehicle. Except as provided in S6.7.1.3, the determination of whether a vehicle would be taken out of compliance with this standard when an individual device is installed on the vehicle is made without regard to whether additional devices, including separate lamps or reflective devices sold together with the device, would also be installed.​

Emphasis added.

CharlesinGA, you might want to request some sort of compensation from AlphaREX for this, if for nothing else, to help them up their game.
 
Last edited:
For got to add two things:

One.

While 49 C.F.R. § 571.108 is "merely" regulatory law (which agencies like the DOT can waive at their own whim), a related statute (which cannot be waived by an agency (unless, of course, the government doesn't care about following the "rule of law" (sound familiar?)) is 49 U.S.C. 30122, which reads:

§30122. Making safety devices and elements inoperative
(a) Definition. — In this section, “motor vehicle repair business” means a person holding itself out to the public to repair for compensation a motor vehicle or motor vehicle equipment.
(b) Prohibition. — A manufacturer, distributor, dealer, rental company, or motor vehicle repair business may not knowingly make inoperative any part of a device or element of design installed on or in a motor vehicle or motor vehicle equipment in compliance with an applicable motor vehicle safety standard prescribed under this chapter unless the manufacturer, distributor, dealer, rental company, or repair business reasonably believes the vehicle or equipment will not be used (except for testing or a similar purpose during maintenance or repair) when the device or element is inoperative.
(c) Regulations. — The Secretary of Transportation may prescribe regulations—
(1) to exempt a person from this section if the Secretary decides the exemption is consistent with motor vehicle safety and section 30101 of this title; and
(2) to define “make inoperative”.​

Emphasis added.

Two.

This exercise has made me aware that I need to add some side marker lamps and reflex reflectors to my Jeep, since in replacing the bumper, some of these might have gone missing!
 
Status
Not open for further replies.
Back
Top