Hella 500 HID Conversion

OK, so I know lots of you have Hella's on your trucks. I'm not sure, but I don't really think I'm the only one who is dissappointed by the light output. I have a set of driving lights and a set of fog lights so I got two 35W, H3, 4500K HID Conversion kits.
http://www.ddmtuning.com/index.php?p=product&id=102&parent=85
Not the easiest conversion, I made it harder than it need to be, but I wanted it to look factory, and it does.
First the reflector assembly must be removed from the housing.

Then, due to the new bulb's added insertion length, you need to remove the lamp holder from the reflector assembly. This is done by straightening the three (3) tabs on the back.

Once removed, remove the inner portion of the lamp holder.

Re-insert the lamp holder, and bend the tabs back.

The main portion of the lamp wiring looks like this:

You are supposed to drill a 7/8" hole for the grommet so the wiring can enter your housing. I though it was kinda dumb to leave the stock power entering the housing, then have another grommet bring the power to the lamp from the ballast, as well as the new power wires to connect right to the old power wires inside the light. I wanted two wires entering the housing only, going to the bulb so here is the mod's to do so.
First remove the grommet from the wiring harness. Cut down the grommet to each wire. When you are done the grommet will look like this.

Now the back portion of the bulb is too long to fit in the housing when installed within the reflector. To rectify this, simply take a dremel and grind a relief down the side of the bulb so the wires can exit the side like this (Note: the lamp is still in the protective case at this time to protect the bulb):


Next remove the grommet from the original wiring for the Hella's.

Now grind off the bosses inside housing to make adittional room within the housing. It should look like this when you're done.

Now enlarge the wire entry hole so the plugs on the bulb can fit through the hole.

Install reflector assembly back in the housing, install the factory grommet around the new wires, add silicone to help seal up the entry of the wires.

Now the assembly for one light looks like this:

Simply hook up the red and black and your in business!
Now repeat for the other fog light...then the other two driving lights...and whollah:
(insert completed re-installed photo of lights on truck here)

 

Nice write up. Thanks

 

You are very welcome, sir.

 

great install, lets get some pics of the lights on now

 

I think your camera's focus function is broken.

 

It's fine, I just shake a little bit and it makes it hard for the camera to focus.

 

so how much brigher are they now. i'm thinking about doing this soon and am wondering if it is really worth it

 

so all you need to power these HID's is a + and -?

is all hid's like this or am i not seeing this correctly?

 

To power HIDs, you need ballasts. They are little boxes that convert power to the HID capsules.

 

Would it be okay to run 6000k conversion on Hellas?

 

Yea you will have no problem with the 6k.

 

Sweet! Thanks!

 

does it really make much difference with the 35w kit vs the 55w kit? my friend told me the 55w does not put out much more light than the 35w kit.

 

anyone know this?

 

i've never seen anyone with the 35w kit but i know my 55w kit is brighter than hell. from half a mile away looking at them it blinds you still. its pretty ridiculous how bright they are

 

are you referring to a hella conversion or in your headlights? also if in the hellas what beam pattern do you have?

 

must have missed that, thanks man!

if i get the 500's can i use the 55W kit in them? im concerned about them getting too hot. has anyone done this or know of the effects?

 

You should n't have a problem with heat, and they will fit as long as the bulb is the same size bulb.

 

just found this is keason1's build.

http://www.tacomaworld.com/forum/builds/46287-keason1-build-4.html#post1486331

 

i have 55w in my head lights and hella's. my headlights aren't that great though cause i had to buy new housing's that would fit the h4 bulbs and i went cheap and got two housings off ebay for 20 bucks so i need to get better ones and then im sure they will be brighter. in the hella's the beam patttern is hard to explain. it defenetly has bright spots but overall they put out WAY more light than stock hella's. ill try and snap a picture of them on tonight and post them on here.