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Hella 500 HID Conversion

Discussion in 'Lighting' started by NwiTACO, Jun 11, 2009.

  1. Jun 11, 2009 at 9:26 AM
    #1
    NwiTACO

    NwiTACO [OP] Big tars, little/no bed.

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    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.
    [​IMG]
    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.
    [​IMG]
    Once removed, remove the inner portion of the lamp holder.
    [​IMG]
    Re-insert the lamp holder, and bend the tabs back.
    [​IMG]
    The main portion of the lamp wiring looks like this:
    [​IMG]
    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.
    [​IMG]
    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):
    [​IMG]
    [​IMG]
    Next remove the grommet from the original wiring for the Hella's.
    [​IMG]
    Now grind off the bosses inside housing to make adittional room within the housing. It should look like this when you're done.
    [​IMG]
    Now enlarge the wire entry hole so the plugs on the bulb can fit through the hole.
    [​IMG]
    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.
    [​IMG]
    Now the assembly for one light looks like this:
    [​IMG]
    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) :D
     
  2. Jun 11, 2009 at 9:54 AM
    #2
    badguybuster

    badguybuster Well-Known Member

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    Nice write up. Thanks
     
  3. Jun 11, 2009 at 2:06 PM
    #3
    NwiTACO

    NwiTACO [OP] Big tars, little/no bed.

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    You are very welcome, sir.
     
  4. Jun 11, 2009 at 3:47 PM
    #4
    RedruM29

    RedruM29 Blinking Car Mod...

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    Just enough, and never enough
    great install, lets get some pics of the lights on now:D
     
  5. Jun 11, 2009 at 4:26 PM
    #5
    Viet2100

    Viet2100 Well-Known Member

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    I think your camera's focus function is broken.
     
  6. Jun 11, 2009 at 7:57 PM
    #6
    NwiTACO

    NwiTACO [OP] Big tars, little/no bed.

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    It's fine, I just shake a little bit and it makes it hard for the camera to focus.
     
  7. Nov 22, 2009 at 5:33 PM
    #7
    Timicha

    Timicha Timicha

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    so how much brigher are they now. i'm thinking about doing this soon and am wondering if it is really worth it
     
  8. Nov 22, 2009 at 5:43 PM
    #8
    Cars0n`

    Cars0n` Well-Known Member

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    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?
     
  9. Nov 22, 2009 at 8:15 PM
    #9
    Viet2100

    Viet2100 Well-Known Member

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    To power HIDs, you need ballasts. They are little boxes that convert power to the HID capsules.
     
  10. Nov 22, 2009 at 8:38 PM
    #10
    neslerrah

    neslerrah Taco lovin'

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    Would it be okay to run 6000k conversion on Hellas?
     
  11. Nov 22, 2009 at 8:39 PM
    #11
    Dellosa89

    Dellosa89 Love peace and Taco Grease

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    Yea you will have no problem with the 6k.
     
  12. Nov 22, 2009 at 8:41 PM
    #12
    neslerrah

    neslerrah Taco lovin'

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    Sweet! Thanks!
     
  13. Feb 23, 2010 at 6:18 PM
    #13
    Cars0n`

    Cars0n` Well-Known Member

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    Kenwood DDX-512 Deck, Boston Acoustics G5 Sub in Ported Bassworx Box, Kenwood eXcelon KAC-X10D Amp, Sirius Satellite Radio, Magellan GPS, DDM 55w bi-xenon headlights, 2 HID Hella 500ff's mounted behind grill, 4 pc ebay Billet grill, Fog Lights (my truck didnt have them stock), Pioneer Speakers 6x9's(front) 6.5's(rear) AFE Cold Air Intake, Hose Clamp Mod, Tailgate Strengthen Mod, Removed Gay Mud Flaps, De-Badged, BHLM, 245/45/20 on velocity wheels. VW865a, Extra D Rings In Box, OEM Cruise Added Optima Red Top Battery
    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.
     
  14. Feb 28, 2010 at 5:42 PM
    #14
    Cars0n`

    Cars0n` Well-Known Member

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    anyone know this?
     
  15. Feb 28, 2010 at 8:43 PM
    #15
    Timicha

    Timicha Timicha

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    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
     
  16. Feb 28, 2010 at 10:05 PM
    #16
    Cars0n`

    Cars0n` Well-Known Member

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    are you referring to a hella conversion or in your headlights? also if in the hellas what beam pattern do you have?
     
  17. Feb 28, 2010 at 10:27 PM
    #17
    Mr. Brown

    Mr. Brown Well-Known Member

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    What is the difference between 55w and 35w kits?
    Our 55w HID kits are 40% brighter than the standard 35w kits.
    The 55W system ballasts are about 1 cm longer than the 35W ballasts.
    55w kits tend to wash out some of the color of the HID bulb due to the light output (for example, a 55w 8000k will look similar in color to a 35w 6000k kit).
    Our 55w HID Kit is not recommended for smaller fog light housings because they tend to concentrate a large amount of heat in a small area.

    From the website he got the bulbs from. I don't know how much this helps, but 40% brighter seems pretty significant.
     
  18. Mar 1, 2010 at 7:08 AM
    #18
    Cars0n`

    Cars0n` Well-Known Member

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    must have missed that, thanks man! :thumbsup:

    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?
     
  19. Mar 1, 2010 at 7:11 AM
    #19
    NwiTACO

    NwiTACO [OP] Big tars, little/no bed.

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    You should n't have a problem with heat, and they will fit as long as the bulb is the same size bulb.
     
  20. Mar 1, 2010 at 7:19 AM
    #20
    Cars0n`

    Cars0n` Well-Known Member

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