2nd Gen Non-Engine/Transmission Improvement for weak headlights?

[JGK]

... Here's the real question: does anybody have a template for cutting the truck headlight bucket for bulb access on the 2nd bulb? I'd guess several of you have done this, did you (or can you) sketch out something for the area to be cut out?



Second question, am I safe running 100w/80w bulbs without taking a chance on melting something?

Charles,



There is no need for a template to cut the bucket. Just cut about a 3 or 3-1/2 inch hole approximately where the second bulb will stick through. You can just hold it up into place and get a pretty good idea. I used a combination of a hole saw and a little jig saw with a thin metal blade to cut mine out. Then I cleaned and smoothed up the cut edge with a moto tool and brushed on some Plasti-dip (liquid rubber dip for tool handles) to seal the edge from moisture.



As for the high wattage bulbs, I ran them for about 3 years. But I had to replace the capsules once or twice because they kept scorching the reflector over time. Then last fall one completely melted down and smoked the whole interior of the capsule and ruined it. Damn near caused a fire from what I could tell of the bulb base and socket! So I've given up on the high wattage bulbs and went back to good old standard Hella halogen bulbs and I really don't notice that much loss of light. I'm tired of replacing capsules!



I've seen 2 or 3 different attempts at better lighting for these trucks including a couple of cheap Chinese projector lens headlights with the cool LED accents and so on and none of them are as good as a well done set of sport lights. I haven't seen a good HID set to compare with, though, but for the price, the sports are hard to beat even if it cost you $500 for the conversion (which mine did and I did my own wiring, separate fuse box, relays, etc. ).



-Jay

 

[MeanMrMustard_GodofThunder]

Does anyone know definitively whether the sport lights or the projection lights are brighter?

 

[JTHosler]

I have been looking and thinking about coverting my headlights to the sport model, but had a couple quick questions. Does the LMC heavy duty wiring harness work on the sport lights with 2 bulbs or do i need one of the other harnesses mentioned? My other question is with one of these harnesses with the relays that get power from the batteries work with snow plow lights and wiring or will i have problems with that? Haven't found much in the way of info on this, so any help is appreciated.

 

[JGK]

Does anyone know definitively whether the sport lights or the projection lights are brighter?

I don't, but I will offer that brighter isn't necessarily better. It's all about how its focused onto the road.



One thing I notced about the sport lights over the stock single-bulb lights is that not only do they light up the road well, they also light up the side area better for spotting other hazards about to get in your way (people, bicycles, animals, etc. ).



-Jay

 

[MRoberts]

I just finished the sport conversion and it is amazing! Easily the best "bang for the buck" BOMB yet.



I picked up a set of Depo aftermarket lights and ordered a wiring harness from Daniel Stern. The harness is very nice, much higher in quality then the harness I ordered from Summit a few years ago.



The light output is amazing, the headlights came with standard Sylvania bulbs and there is no reason to change them. If you go to Sterns site, he explains the different "hotter, whiter" bulbs. Save your money!



I would have preferred to buy the OEM lights but they were $$$. The Depos fit perfectly and I'd be hard pressed to tell the difference between the two.



Here is a pic:

 

[JGK]

Does anyone know definitively whether the sport lights or the projection lights are brighter?

I don't, but I will offer that brighter isn't necessarily better. It's all about how its focused onto the road.



One thing I notced about the sport lights over the stock single-bulb lights is that not only do they light up the road well, they also light up the side area better for spotting other hazards about to get in your way (people, bicycles, animals, etc. ).



-Jay

Let me modify my response a bit. A friend has the Chinese projector lights he got off eBay and I have the sport lights. In my opinion my sports are a superior set up. His are a bit more focused but not necessarily brighter. Mine shines a nice, bright, broad beam that really works quite well. His was certainly cheaper - there was no additional wiring involved. But I think he'd agree my sports are a better lighting option.



-Jay

 

[bubba_zanetti]

My 96 had the decaying yellow lights...

I got some junkyard Sport lights, and the SUVLIGHTS wiring harness.

Wow did that ever improve things... in fact I had a low beam bulb go out and didn't even notice for a month.

The wiring harness uses relays to bring power directly from your batteries to the bulbs... all your light switch does is turn on the relays. Gives your switch longer life, and gives the bulbs higher voltage (no loss through the wires and the switch).

I got a second set of sport light housings through Ebay for another vehicle... the Depo ones... they seem identical to my junk yard ones.

BTW, after a few years, my junkyard housings (well one of them) started to cloud on the outside... I bought this headlight rejuvenator from wallmart (they sell it at most, but not all stores).

It has two different fine grits of sand paper, and a polishing compound... and also a clear resealant type substance.

It actually worked, it looks good as new... so if you have the yellowing or scratched housings, give it a try.

 

[ed9824v]

My 96 had the decaying yellow lights...



I got some junkyard Sport lights, and the SUVLIGHTS wiring harness.



Wow did that ever improve things... in fact I had a low beam bulb go out and didn't even notice for a month.



The wiring harness uses relays to bring power directly from your batteries to the bulbs... all your light switch does is turn on the relays. Gives your switch longer life, and gives the bulbs higher voltage (no loss through the wires and the switch).



I got a second set of sport light housings through Ebay for another vehicle... the Depo ones... they seem identical to my junk yard ones.



BTW, after a few years, my junkyard housings (well one of them) started to cloud on the outside... I bought this headlight rejuvenator from wallmart (they sell it at most, but not all stores).



It has two different fine grits of sand paper, and a polishing compound... and also a clear resealant type substance.



It actually worked, it looks good as new... so if you have the yellowing or scratched housings, give it a try.

I am still confused if depo is a sellers name or a type of light. do you have a name or site for the seller of these sport headlights thanks Ed

 

[Thomas]

Virtually all aftermarket lamps that mimic the second-generation OEM Sport lamps are made by DEPO (DEer POrt, Taiwan). They are distributed in the USA by Maxzone.

 

[ed9824v]

Virtually all aftermarket lamps that mimic the second-generation OEM Sport lamps are made by DEPO (DEer POrt, Taiwan). They are distributed in the USA by Maxzone



thanks for the help was bothering me Ed

 

[WrenchRat]

Well, thanks to all the folks who replied with info and their story. I finally ordered all the stuff to make the conversion from standard single bulb 9004's to the OEM Sport set-up with the 9004's and 9007's.



I ordered the harness from SUVLIGHTS and just got it. For the 1999, it is actually TWO harnesses, one for each side. Good for those of us with dual batteries. Looks like it is decently made. Comes with hot leads that go directly to the battery, 25amp fuses and relays for BOTH circuits. Looks to be a 'plug in' set up. If it works, it will be worth the $148 total cost delivered, as I could not have come up with all the special connectors, correct lengths and gages of wire, fuses, relays and such for that $$.



Only complaint is that all of the terminaled wire ends are not shrink wrapped. Yeah, that might be a little picky, but it is the right way to make such things. I had considered Daniel Stern but was unable to get clarity on exactly what their product was comprised of. The Daniel Stern site is a must read on light technology.



The lights were ordered from CAR PARTS WHOLESALE, P/N D100125 and D100126, for a total cost of $317 delivered. I expect them to look just like MROBERTS picture above. At least that's what the web pics looked like. These are not in yet, so no comments. I would guess they are the DEPO variety that is in wide aftermarket distribution.



I've been hemming and hawwing over spending ~$500 on lights for months...



What finally took this over the hill was my wife riding with me one moonless evening in the country with wet pavement and a hint of fog, and she asked me if my lights were even ON! I said of course they are (fogs too) and she said "These lights are dangerous, I can't see anything, please turn on your 'blasters'. " (The 'blaster's' are my 100W KC Daylighter's) Well, that started the discussion about how to fix the problem. Thanks DW for getting this going. :-laf

 

[charlessmith]

I finally got my aftermarket Sport Lights installed in the '96. This is such a major improvement it should be on the TDR list of things "You Have To Do", right up there with the KDP fix!



I ordered the SUVLIGHTS wiring kit, and it took a couple weeks to get but it surely does the job.



I installed the Sport Lights and wiring kit before I cut out the headlight buckets. All it took was to leave the 9004 bulbs out of the lights. I taped over the bulb openings for a few days. It was much easier to adjust the lights with just the 9007 bulbs being used. I was concerned about possible glare to oncoming drivers when lighting both the 9007 and 9004 filaments for low beam, but it doesn't seem to be a problem.