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HOW TO-Hella 500FF HID Conversion

Discussion in 'Lighting' started by jTrimmell, Aug 21, 2011.

  1. Aug 21, 2011 at 6:10 PM
    #1
    jTrimmell

    jTrimmell [OP] "Don't worry we have airbags!!"

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    Joshua
    Oklahoma/Kansas
    My first project posted to the Forum!

    So I wanted to upgrade my Hella 500FF's to HID to try and get some more output out of them. I bought a Xentec H3 35W 6,000K Slim Ballast kit for about $35. Xentec is the only brand I have used and NEVER had a problem with them and their kits are covered by a 2 year warranty if you ever need it.
    -Hella 500FF's --$60--
    -Xentec H3 35W Slim Ballast 6,000K Kit --$35--
    -4 1" Gromets from Napa --$3--
    -Big Strech Black Sealant --$6--
    Total--$104--

    Pulled my lights off the truck for the conversion.
    [​IMG]
    Took the screw out of the plastic lens retainer on the bottom of the light.
    [​IMG]
    [​IMG]
    Then I pulled the wires back through the rear part of the housing and set the rear part of the housing aside for now.
    [​IMG]
    Then I pulled the metal keeper loose that holds the bulb in and removed it. You can't reuse it as the rear part of the bulb is to long and its physically impossible.
    [​IMG]
    Here is a pic of everything I will be using.
    [​IMG]
    With the metal retainer clip removed since it won't work I just bent the metal prongs over against the base of the bulb and then wrapped a small zip tie around them to hold the bulb in. I got it as tight as I could.
    [​IMG]
    Then I drilled a 7/8" hole in the exact center of the rear of the plastic housing since the rear part of the bulb is to long to fit under the housing unmodified.
    [​IMG]
    Perfect fit!
    [​IMG]
    Front pic of the bulb installed.
    [​IMG]
    I bought a tube of Big Stretch Sealant at the lumber yard. Its a greyish/black color, will stretch twice its size before it tears and is removable if a bulb goes bad.
    [​IMG]
    Then I put a good layer of the sealant around the base of the bulb and let it set up for 20 minutes.
    [​IMG]
    I bought some 1" gromets at Napa for $2.99. They fit great in the hole but are kinda deformed from the rectangular shape of the base of the bulb.
    [​IMG]
    Then I put the sealant around the gromet and sealed it up. I also made sure to seal up the old gromet.
    [​IMG]
    Lights installed back on the truck.
    [​IMG]
    I mounted the ballast on the radiator core support using the supplied adhesive strips.
    [​IMG]
    Hooked the wires up to the Hella harness and ran them down the core support and behind the battery box up the firewall.
    [​IMG]
    Much brighter then they were!
    [​IMG]
    They are a little bluer than I wanted but they will work!
    [​IMG]
    [​IMG]
    Night shot.
    [​IMG].
     
  2. Aug 22, 2011 at 12:43 PM
    #2
    Tackleberry

    Tackleberry Rifleman not a cook, Appleseed program

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    Mark
    Shelton, CT
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    Tacoma 2011 DC long bed Mag Gray
    Extang Trifecta Tonneau Cover, Toyota OEM Roof Rack, Console Vault, Weathertech floor liners, LUND bed extender, Gauge pod, Outside Temp, Enviro gauge, Maglite mount, J-hooks for scope stand, MetalMiller's Devil Horns, AVID Light Bar and Side Steps, Pop-N-Lock, Westin Driving lights, Hella 500 Off Road lights, Tacoma Bed Liner, Door Trim Guards, LED dome, map and plate lights
    Thanks for the great write up. Nice work and a very cool looking truck!
     
  3. Aug 23, 2011 at 8:36 PM
    #3
    jTrimmell

    jTrimmell [OP] "Don't worry we have airbags!!"

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    Thanks man!!
     
  4. Sep 28, 2011 at 1:13 PM
    #4
    mudthedoor

    mudthedoor Sconnie

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    Alex
    Forestville, WI
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    00 4Runner
    do you have any pics of the lights aimed down range?
     
  5. Sep 28, 2011 at 1:15 PM
    #5
    Tigahshark

    Tigahshark Senior NEWBIE

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    Isaac
    On a volcano, literally!
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    2011 DC TRD off road 4X4
    Tint Weathertech floor liner, weathertech window visor Roll n lock tonneau cover Rubber bed mat Smoked license plate covers
    Nice detailed write up! Ram looking cherry
     
  6. Oct 4, 2011 at 7:55 PM
    #6
    jTrimmell

    jTrimmell [OP] "Don't worry we have airbags!!"

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    Don't have any of them aimed down range.. I would snap one tonight but the truck is sitting at the lady friends dads house hooked up to their enclosed trailer. But I will snap one tomorrow for sure!

    Thanks man!
     
  7. Oct 20, 2011 at 10:15 PM
    #7
    jTrimmell

    jTrimmell [OP] "Don't worry we have airbags!!"

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    Sorry guys! Been crazy busy with my dads company, trying to get hired on with some departments and with school work. I'm taking 16 hours this semester, working for my dads company, helping him run his side line business and run my business at the same time while maintaining my sanity by hanging out with the friends. I'm just getting caught up on the forum's so here are some pics of the lights pointed down range! They aren't the best because I keep them pointed down and in a little bit. They are a long range light for sure. They will also be for sale here pretty quick. Got a crazy deal on a couple Light Force 240 XGT HID's!
    [​IMG]
    [​IMG]
    From the stop sign in the second picture all the way in front of the truck to the end of that road where one of our storage containers is sitting is roughly 200 yards for reference. Truck is 3ft. higher then the road is down by the storage container and the lights are angled down so you can see that they would go much farther if adjusted up a bit.
     
  8. Sep 30, 2012 at 8:51 AM
    #8
    T@co_Pr3runn3r

    T@co_Pr3runn3r XXXXXXXXXXXXXXXXXXX

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    <----------------->
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    sub......another project that needs to be knocked out. (no actual thread revival in progress...)
     
  9. Oct 1, 2012 at 12:16 PM
    #9
    jTrimmell

    jTrimmell [OP] "Don't worry we have airbags!!"

    Joined:
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    Joshua
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    I see how it is! Going to delete my first how to thread haha!
     
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