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The ultimate foglight upgrade H11 (not LED or HID)

Discussion in '2nd Gen. Tacomas (2005-2015)' started by crashnburn80, Jun 4, 2016.

  1. Jun 4, 2016 at 2:38 PM
    #1
    crashnburn80

    crashnburn80 [OP] Vehicle Design Engineer

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    For those that have not read my headlight thread the build goal is the same, but relates to fog lights instead: Drastically increase the light output from the stock lights without sacrificing quality, durability or the OEM lighting optics.

    Version 2.0
    Coming soon - I am working on a major update to this mod to make it better in hopefully almost every measurable way. Should have published results and thread updates in mid-late Feb 2019.

    You can see some info and updates starting in post #378 here.

    Version 1.0
    3rd Gen Headlight Note:
    This H11 foglight upgrade also works for 3rd Gen H11 low beam headlights. You can see 3rd gens results posted later in this thread, here and here. Also see the dedicated spin off 3rd Gen headlight thread.

    For reference: The Ultimate headlight upgrade thread.

    The recipe is the same. Turn up the power up to 11, drop the resistance to increase effective voltage to the bulb resulting in greater light output and use superior quality halogen bulbs and components, while maintaining proper beam cut offs and fullness of the beam pattern. This mean significantly more light output without glare to oncoming drivers.

    This upgrade results in a measured 2x improvement over stock.

    Ultimate left, stock right (with headlights disabled, fogs only. Additional output pics later in post)
    IMG_5322.jpg

    Compare to the leading Morimoto XB LED Tacoma fog conversion. Output is advertised as 2400 lumens, but if you read it closely you will see it is 1200 raw lumens a side, or about 600-700 actual lumens per side. This upgrade results in a 100% improvement over stock, or 2100+ lumens per side, 4200+ lumens combined.

    Projection angle
    A major difference between OEM H11 fogs and aftermarket fogs is that the OEM H11 fogs are 'wide angle' meaning they project at a measured side angle of 75 degrees, whereas aftermarket fogs are typically around 45 degrees. The wide angle ones then give much more side area coverage,

    The Details:
    The H11 55w bulb used in the Tacoma 2012-2015 fogs is a less than ideal bulb option, terrible for aftermarket support compared to the H4. So finding quality high output alternatives was challenging.

    Bulbs:
    Many people will say to just use an H9 bulb for the fog. However the H9 is a high beam bulb with no end caps or low beam shields and will emit glare as it is not designed to have a controlled beam pattern like a fog or low beam. I will also not use coated bulbs to 'appear white' for cosmetics at the cost of performance or quality.

    Looking for the highest output non-coated quality H11 bulbs led me down one path by process of elimination, German made Flösser 90w H11s. These looked to outperform every other H11 bulb on the market, with only one catch. They are not imported into the USA. However, our capitalistic friends at eBay have some vendors that gladly bring these German bulbs into the USA, making them available to us when no-one else does.

    Stock left, Ultimate right
    IMG_5305.jpg

    IMG_5304.jpg

    IMG_5307.jpg

    The harness:
    Searching everywhere I could also not find a robust H11 harness sufficient to what I wanted to run on my truck. On my truck quality is indisputable king. I contacted my friends at Rallylights and they also had no such harness available. When pressed to source the parts for the harness I wanted to build to my specs, they checked with their suppliers but could not get the H11 male connectors from their supplier for a complete plug and play solution. Only wanting a complete plug and play option, I drop shipped a handful of H11 male connectors to Rallylights and contracted them to build the ultimate 12 gauge Hella foglight harness as a complete custom order. What I received in return was the best, made in the USA, H11 harness money could buy. Robust 12 gauge wiring to minimize voltage drop and increase light output, Hella relay, ceramic connectors. I did drop ship several extra male H11 connectors to Rallylights, so for the first few custom H11 harness orders to rallylights from TW, I've got the connectors covered for you. Later orders will have to provide their own.

    IMG_5303.jpg

    Since my headlight harness ran across the upper core support rail, I ran the fog harness down along the lower impact frame rail, using zip ties to hold it in place. Entire install took about an hour.
    IMG_5311.jpg

    Testing Output:
    Wanting quantitative data for light output increase, I invested in a lux meter to measure light output. For the actual measured light output between bulbs:
    Stock fog lux: 237
    Ultimate fog lux: 475. 2x improvement over stock.
    The LEDs do not even come close, not to mention the 'whiter' light is a less than ideal color temp for fog use.

    Stock lux reading 237 using a ~12" paint stir stick as a standard distance for measurement:
    IMG_5325.jpg

    Ultimate lux reading 475 using a ~12" paint stir stick as a standard distance for measurement:
    IMG_5323.jpg

    Heat:
    Heat is always a concern in the high powered halogen game. I tested the output side by side after idling for 15 minutes to ensure max temp, with an IR heat gun:
    Stock: 185 degrees
    Ultimate: 239 degrees
    Ambient temp: 75 degrees.
    For reference: Polycarbonate softening point (fog lens): 293 degrees

    Yes I am pushing the envelope but I do not anticipate using my fogs when it is over 105 degrees where softening point could start to become an issue. Especially when factoring moving to have a cooling airflow over the lens.

    Stock:
    IMG_5321.jpg

    Ultimate:
    IMG_5318.jpg

    I also researched other aftermarket fog housings like the Spyder projector fogs. Beam pattern and quality never seemed equivalent to OEM and resulted in poorer lighting performance, and seals failing resulting in water inside in the lens, meaning it is an inferior product.

    I will report long term durability back to this thread as I have not used these bulbs before (as I had my headlight upgrade).

    If you want to repeat this mod:
    Contact Ray at Rallylights by using the contact form: http://www.rallylights.com/contacts
    Select "Electrical" in the drop down and mention you want the Tacoma H11 Fog harness. If you are one of the first few that get my connectors, it should come out to about $69 shipped.
    Update:
    Or call Rally Lights at (610)944-3233 ask for Ray and tell him you would like the HL282H11 Wire harness.
    Update: Ray has since retired, but the harness is still available through Ralleylights.

    Relay upgrade - Update 11/25/18
    The Rallylights harness uses German brand Hella relays made in China. I'm always skeptical of made in China part quality and do my best to avoid those parts. @Norton had his Hella relay fail after a couple years and did some leg work to find a high quality alternative. You can see his post with photos here.

    The recommended replacement is the Bosch 332019150 Relay, made in Portugal.

    20181123_143621.jpg



    Image above is from Nortons post. For the $7 it is a worthwhile preemptive upgrade IMO. I've purchase one to replace my working Chinese Hella relay. It is worth noting that Headlight Services, who builds headlight harnesses used in the headlight upgrade thread strives to use only the highest quality components, and they use the same European made Bosch relays.

    Why not LED retrofit:
    LEDs and HIDs in halogen reflector fog threads have become a popular mod. This results in glare everywhere and is dangerous to oncoming drivers. If you are unfamiliar with why this is a bad practice, read this thread to see why, and how a halogen upgrade compares to an LED one:
    https://www.tacomaworld.com/threads/why-leds-should-not-be-run-in-halogen-reflectors.454371/

    If wanting to do an LED conversion the entire assembly needs to be replaced with one designed for an LED light source, see this thread for nearly all available options:
    https://www.tacomaworld.com/threads/the-led-sae-j583-fog-pod-fog-light-review.554813/



    Output of headlight upgrade + foglight upgrade:
    The problem with wall pics is that the light output always seems to wash out the camera, using an iPhone 6s, which is supposed to take billboard quality photos. Keep in mind I am running my headlight upgrade as well.

    The ultimate headlight upgrade plus the ultimate foglight upgrade, pushing near 9000 lumens in combined output. Note the full saturation of the beam pattern:
    IMG_5353.jpg

    When I mentioned that the output is not as useful as the headlight upgrade, it is because the significant benefits seem to be in the peripheral illumination. But I am also running significantly more powerful headlights than stock.

    45 degrees out the driver side, Ultimate headlight upgrade only:
    IMG_5349.jpg

    45 degrees out the driver side, Ultimate headlight upgrade plus ultimate foglight upgrade:
    IMG_5351.jpg

    Update with some more output pics on dark roads:
    IMG_5357.jpg

    IMG_5359.jpg

    Other bulbs
    GE H11 Megalight +130 is by far the best performing stock wattage H11 bulb I have tested. See this post. They even outperform H9s in the 3rd gen headlight assembly. I still need to test these in the fog assembly, they may replace Volsa H9s as the recommended bulb.

    I'm often asked for bulb recommendations for "whiter" high power bulbs. I recommend non-coated bulbs, but for those looking for a whiter bulb there is Optilux 80w H11. Not Recommended. See my experience with Optilux.

    Yellow bulbs: Optilux makes a glare caped yellow H9. H9 is an extremely high performance bulb, I have better faith in a stock wattage high performance bulb than a high wattage one, but I have not tried these myself.
    Optilux 65w yellow H9

    Nokya also makes a 75w H11 3100k 'stage 2' bulb.

    Other lighting upgrades
    If you found this interesting you may be interested in my other lighting threads.

    Fog light upgrades:
    The LED SAE J583 Fog Pod & Fog Light Review
    The H10 to 9011 HIR Foglight upgrade (better than LED)

    Other lighting upgrades:
    3rd Gen HID vs LED vs Halogen H11 projector headlights
    The ultimate headlight upgrade H4 (not LED or HID)
    Gy6.35 HIR 921 reverse light upgrade (vs high power LEDs)
    The 921 LED Reverse Light Bulb Study

    More information on automotive lighting:
    Automotive Lighting 101
    Why LEDs should not be run in Halogen reflectors

    Home lighting upgrades:
    High quality efficient home lighting using LEDs, HIRs and Halogens

    I am always happy to help anyone on their truck project. Please do not hesitate to PM me with your questions or post them here.
     
    Last edited: Feb 12, 2019
  2. Jun 4, 2016 at 3:00 PM
    #2
    Norton

    Norton Senior Member

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    Very nice! Been looking for this ever since installing your ultimate headlight upgrade... Thanks for doing all the leg-work!

    How's the install itself (i.e., routing wires)?
     
    crashnburn80 [OP] likes this.
  3. Jun 4, 2016 at 3:01 PM
    #3
    crashnburn80

    crashnburn80 [OP] Vehicle Design Engineer

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    How could I forget the wire routing pics! Will update the original post.
     
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  4. Jun 5, 2016 at 12:12 PM
    #4
    crashnburn80

    crashnburn80 [OP] Vehicle Design Engineer

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    First driving impressions, a notable improvement in light output and a great continuous light pattern from the fog beams to the headlights. Not quite as much of a useful upgrade as the headlight upgrade. Still need to get pics on a dark road.
     
    Last edited: Jun 5, 2016
  5. Jun 6, 2016 at 11:18 PM
    #5
    LeftCoastNerd

    LeftCoastNerd Old 'nuff to know betta

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    my favorite aftermarket projector fogs are the Hella MicroDE, which are available in halogen or HID. these are metal bodied, glass lens, very compact, very good wide patterns. they also make MicroDE Driving Lights, these are long distance spotlamps.

    here's one on a custom mounting block[1] on my bike. I installed these lights in 2003, and have driven 50000 miles in all kinda weather with them, they've never let me down. in 12 years I've replaced 2-3 sets of high wattage yellow H3 bulbs.
    IMG_1792half[1].jpg IMG_5676-L[1].jpg


    [1] a wedge of delrin, hahaha. These are meant to be mounted behind the bumper
     
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  6. Jun 6, 2016 at 11:29 PM
    #6
    crashnburn80

    crashnburn80 [OP] Vehicle Design Engineer

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    Nice BMW bike. I'm curious to which bulbs you are running, not that H3 is an option for stock reflectors. I'd be very surprised if they could out preform the 90w Flossers, as an H3 produces about 1000 lumens, or roughly 1/2 of the output of the 90w flossers.

    I spent a lot of time on this project. I would challenge anyone to out-preform my fog output at a lower cost, while maintaining the correct beam pattern.
     
    Last edited: Jun 6, 2016
  7. Jun 7, 2016 at 12:08 AM
    #7
    LeftCoastNerd

    LeftCoastNerd Old 'nuff to know betta

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    I ran Hella 85W yellowstars for awhile...
    http://www.amazon.com/HELLA-HLA-H83135081-Yellow-Star-Single/dp/B000COBLGQ
    but they were too bright on truly dark nights for me, so I reverted to the standard 55W yellowstars, plenty bright enough. I have them on their own switch, but the bike's parking light has to be on (which is on with or without the headlights, unless the headlights are switched completely off).

    In coastal/mountainous central/northern California here, we have a LOT of deer. these provided side light for seeing said deer in the dense woods on both sides of narrow mountainous roads. also acted as general conspiquiity lights as I pretty much left them always-on during the day, so they formed a triangle with my headligth to give my oncoming motorcycle more substance.
     
  8. Jun 7, 2016 at 12:42 AM
    #8
    Backt

    Backt Well-Known Member

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    @crashnburn80 I love the ultimate headlight upgrade since I started running it last fall. I definately want to give this a try to.

    Am I reading the OP correctly that this upgrade cost less than a $100?

    As I learned from the headlight upgrade bulb life was pretty short on my first set. Do you have any idea about how long these should last. Obviously they won't be on all time but are they rated for a certain number of hours?
     
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  9. Jun 7, 2016 at 12:51 AM
    #9
    LeftCoastNerd

    LeftCoastNerd Old 'nuff to know betta

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    my long time experience on multiple vehicles suggests quality name brand 80-100W car lamps will last maybe 500-1000 hours, while the regular ones last 5-10X that. you can tell halogen bulbs are getting old when the inside of the capsule darkens.
     
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  10. Jun 7, 2016 at 1:59 AM
    #10
    LeftCoastNerd

    LeftCoastNerd Old 'nuff to know betta

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    oh, here's another pair of them on my 1992 volvo 740 turbowagon, which was my utility vehicle before I got the tacoma.

    IMG_0124-X3[1].jpgIMG_0122-S[1].jpg
    (but that closeup was a trial mount before I recessed them into the bumper trim)

    these have 55W Hella yellowstars in them. pale yellow, makes a great foglamp. photo was taken from right at the edge of the beam cuttoffs.
     
    Last edited: Jun 7, 2016
  11. Jun 7, 2016 at 9:47 AM
    #11
    crashnburn80

    crashnburn80 [OP] Vehicle Design Engineer

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    Correct. The entire upgrade is less than $100 shipped, if you are one of the first to order the harness from Rallylights with the extra connectors I provided them. If not, you will have to ship them your own connectors for a plug and play product or just use spade connectors on the exposed blade terminals.

    I do not have an hour rating on them, and this is my first time running these bulbs so I cannot provide a historical reference point like I could on the other Osram bulbs. I'll update the thread when one fails to provide some life expectancy data. I would not expect them to last anywhere near as long as the OEM ones, with the heat in the smaller fog I'd be happy if they last a year.
     
  12. Jun 7, 2016 at 12:11 PM
    #12
    justchil

    justchil Well-Known Member

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    Having a hard time finding bulbs. Anytime I find something 70w or higher it's a 24v bulb. If anyone happens to find a good US source please feel free to post.

    I inquired about the harness too. I am currently running OPTILUX HL88411 H11 12V 55W (Yellow 2500°K) bulbs that are due to be replaced.

    Edit: Found them DOH
     
    Last edited: Jun 7, 2016
  13. Jun 7, 2016 at 12:53 PM
    #13
    Cmurder

    Cmurder 2011 TX TRD Offroad

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    nothing cool
    Awesome work.
     
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  14. Jun 7, 2016 at 12:59 PM
    #14
    crashnburn80

    crashnburn80 [OP] Vehicle Design Engineer

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    High wattage non-coated quality H11s were difficult to find. OPTILUX does have some 80w H11s, but they are blue.

    This was the best I found.

     
    Last edited: Jun 7, 2016
  15. Jun 7, 2016 at 1:00 PM
    #15
    justchil

    justchil Well-Known Member

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    I'm not sure if I changed my search filters or what but I see them listed now on ebay. Cheers!
     
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  16. Jun 7, 2016 at 8:08 PM
    #16
    crashnburn80

    crashnburn80 [OP] Vehicle Design Engineer

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    I think all my connectors may have been spoken for already. Rallylights might be more motivated to source parts now. If not, you can purchase H11 male connectors off eBay (only place I could find what I wanted in not massive bulk) and ship them directly to Rallylights to have the harness custom built.
     
  17. Jun 7, 2016 at 8:20 PM
    #17
    justchil

    justchil Well-Known Member

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    10-4 appreciate the info. I'll snag the bulbs for now and work on the rest as time allows.
     
  18. Jun 7, 2016 at 8:21 PM
    #18
    crashnburn80

    crashnburn80 [OP] Vehicle Design Engineer

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    Ping them anyway. If there is a market a good business will provide a solution.
     
  19. Jun 7, 2016 at 8:51 PM
    #19
    Norton

    Norton Senior Member

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    Interesting. I've pinged them at least twice, including the night you started this thread. They have yet to respond to my messages.
     
  20. Jun 7, 2016 at 9:35 PM
    #20
    crashnburn80

    crashnburn80 [OP] Vehicle Design Engineer

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    Then you are on the list I'm sure. Ray wanted to confirm fitment before responding to orders I think. There were some minor tweaks to the length to make it perfect as I was the guinea pig.
     
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