2nd Gen Non-Engine/Transmission Sport H/L Conversion How To

[crabman]

I installed my sport conversion head lights with 2 HD wiring assemblies yesterday. Some info for those of you who are still driving with the POS stock lights it is worth the money.



Parts:

Got sport head light assemblies from Import lights.

All electrical parts from SUV.

12 gauge marine wire was used to assemble wiring harnesses which connect directly to each battery and operated through a relay.



Installation Process:



I removed the front stock bumper, 6 bolts and it's off.

Removed stock h/l's, 3 screw bolts

Measure over toward radiator 1 inch from edge of existing circle for stock light. Make sure it is centered and use a punch to mark it.

Use a 3 1/2" hole saw and cut out hole. Note: some places it is 2 layers thick.

After hole has been cut I used a sawsall with a new metal cutting blade to cut straight across to take out whats left.

Cleaned up cut out with drum sander and file so ALL edges were smooth.

Hooked up wiring harness to battery and plugged all wiring harnesses together. (before plugging together I put dielectric grease in all female connections)

Check to see if light worked and installed.

Same for other side and reinstalled bumper.

Total time 2 to 3 hours

Since I had not done this before and I sort of figured out what I had to do as I went along the total installation time could be cut by 30% easily.



The SANO wiring harnesses were already made up. (THANKS DAVID!!)

Now, while driving at night I am instead of

crabman

 

[Tardog]

Yup nothing like actual headlights to drive with. Here is a picture of the cut out for anyones interest.

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[crobertson1]

Are they really that much better?

 

[crabman]

Tardog,

Nice, looks like a sano job too!

C1,

In a word, YES!

I had a brite box which was ok if you had your brights on, but on dim it was like having a flashlight for headlights.

crabman

 

[Tardog]

Thanks Crabman, actually I made my own harness and connections, Our Canadian trucks work a bit different because of the daytime running lamps (voltage sensitive to the high beams).



CI, yes there is no comparission. Plus the sport lights give you some extra options like "8" filiments on highbeam at 65 and 45 watts = 440 watts without going to higher wattage bulbs. I find the side light much better with the sports. They take a little to get adjusted right because they seem to have different patterns left and right. If you do any night driving you won't be dissapointed.

 

[dresslered]

The SANO wiring harnesses were already made up. (THANKS DAVID!!)

Glad they worked out for you! I know that the 8 LARGE live crabs that showed up on my doorstep, sure worked out for me. (THANKS CRABMAN!!)



I'm sure that you took care of this point, but I thought that I would just emphasize it since it was missing from your procedure, is to prime and paint the new cutout area. Without doing so, especially on the coast, the rust will surely set in. Also, on the newer trucks (I believe 2000+) the cutout is not required.

 

[edgrim]

Sportlights

Did mine on Thursday nite alone with just advice I read here,which was great! Saturday night I drove 200 miles from 8:45 PM to12:30 AM in blinding snow storm lights were wonderful.

My wiring harness wasn"t in yet (my fault) so I can't wait to install them next. By the way I only used a cordless saws-all didn't have help to pull bumper so I just worked the lights around.

 

[jeepit]

What is website for import lights??

 

[pgleavitt]

importvision.com

 

[rrausch]

Tardog, could you post a picture of what it looks like when it is done?

Or Crabman, perhaps you could post a finished picture. I'd like to see the finished product if possible. Thanks.

 

[Tardog]

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A few more pictures can be found in my readers rigs