Foretravel Owners' Forum

Prolet  asked to go in more detail about my Bronco headlight conversion. I sourced my projection system from The Retrofit Source. The Retrofit Source | The Best HID & LED Projector Headlight Upgrades (https://www.theretrofitsource.com) The 1991 Bronco received the HID BI-XENON: ACME H1 STANDARD PROJECTOR SYSTEM. $130.00. The kit was straight forward to install but will require some basic hand tools. A drill and heat gun. I also polished the prisms and resealed with Amazon.com: Dupli-Color (HLR100-3 PK Clear Headlight Restoration Kit - 10... (https://www.amazon.com/Dupli-Color-HLR100-3-PK-Headlight-Restoration/dp/B00B3UZ6U0/ref=sr_1_24?keywords=headlight+restoration+spray&qid=1575222710&sr=8-24) $38.00
The web sight has nice detailed installation instructions and prior I had never performed this before.
1. Remove the headlight bucket from the vehicle. Careful not to damage adjusters.(Brittle)
2. Clean out side, you will be handling a lot and will need to stay clean.
3. Take heat gun and slowly raise the temperature of the butyl around the perimeter of the bucket. Leather gloves were used for the heat. Gently separate the lens from the reflector. Gently remove/scrape the butyl till removed. Reapply heat as required.
4. Notice on the inside of the lens is covered with prisms that Ford placed to correct the poor quality of the bulb and reflectors. I removed the prisms with sandpaper finishing up with 1000 grit wet and dry. At this point I realized I had destroyed the clarity of my lens. In complete amazement I used the Duplicolor restoration kit and like magic they were clear again. Follow directions on box.
5. Follow directions on installing projector in the reflector. A small hole will be drilled thru the lens to allow a high beam signal wire to pass thru.
6. I sealed the projector  unit and hi-beam signal wire with clear RTV. Used the same to replace the Butyl for the lens and reflector assembly . Allowed to fully cure.
7. Wiring plug will need to be changed and the Hi beam signal wire hooked up. In Hi beam it opens a shade/door that covers the upper half of the projector.
Note; At this time I was into my third day with probly three hours involved to install, mostly sand, polish and finish lens to clear. Most of the three days was watching sealant and paint dry. 
The illumination is very flat and standing in front of them in low beam  minimal glare until you enter the plane of light. The one photo shows the stock light Output unmodified.
High beam is as good as I've ever seen. 350 foot driveway is brilliant. Does produce a lot of glare.
I did order another Kit this week that will be installed in my daily driver BI-LED: MORIMOTO M LED2 $350.00 Bi-LED: Morimoto M LED 2.0 - LED Headlight Retrofit Projectors from The... (https://www.theretrofitsource.com/bi-led-morimoto-m-led-2-headlight-projectors.html)
I'll try to document better.

Thanks for the post, DSD.  Now that's a headlight conversion worth spending a few hun on...that illumination comparison picture says it all!!!  I'm gonna hit the junk yards to get a couple or 4 old Bronco headlight buckets to hack up and convert while I'm sunning in Quartzsite this winter!  I may do the high beams too.  Woody.

I wouldn't waste the time getting old lens. Get some new ones preferably with no prisms.
Scott

Just found this on Amazon...another headlight conversion option I'm pondering.  Might update the look and improve the optics of the pitiful 87-91 Ford buckets, but since Chinee, I doubt it.  Currently cheaper than the Depo OEM buckets.  Will post pix if I get 'em.  Woody.

Amazon.com: Pair OE Style Black Housing Amber Side Headlight Corner Lamp for... (https://www.amazon.com/Style-Housing-Headlight-Corner-Bronco/dp/B0821WMFB4/ref=pd_day0_hl_263_1/132-2508346-1747528?_encoding=UTF8&pd_rd_i=B0821WMFB4&pd_rd_r=4972c5a0-f4d2-4a9d-b95e-877c555bfa18&pd_rd_w=r8YJA&pd_rd_wg=LKPbW&pf_rd_p=0501877d-5f8c-4ec8-9861-e0476eecc53e&pf_rd_r=69KTXZJ6XCBA3Q10JR6Y&psc=1&refRID=69KTXZJ6XCBA3Q10JR6Y)

I did this HID conversion on our 1993 U300 back in 2014. Pretty easy but I ran a #10 down to the CB from the ignition solenoid. Wiring took a few minutes to figure out but it works well. Polished the lens with shop buffer and HD compound. Needs to be polished each year to stay nice and clear. Cost was about $40 for the kit. They are VERY bright. A slight blue cast to them, about 4000-4500K as I remember. Relay is the small black box in the top left of photo #2

Pierce

Woody. Yes those are what I would recommend. No prisms
Pierce. I wasn't happy with the non projector hid's because of the poor focus. Ford put those small prisms to correct for poor reflector and light bulb design. With the Hids you get a lot of unfocused light and the oncoming traffic will curse you as you do others with similar light. I just got the next new LED2 from The Retrofit Source. New release Projector LEDs that are both legal and nice to use. Very defined focus with no light leakage above the headlights to oncoming traffic on low beam.  Still haven't fired them up but trying to get to them. They actually use a door to cover the light during low beam. Bi-LED: Morimoto M LED 2.0 - LED Headlight Retrofit Projectors from The... (https://www.theretrofitsource.com/bi-led-morimoto-m-led-2-headlight-projectors.html)
Scott

Scott,

You are probably right about the light leakage. The problem with the GVs is how high the headlights are mounted. They are bright for oncoming cars and I do occasionally get flashed. Huge difference though.

I always kept the Euro headlights in the grey market cars I had for personal use. We would replace the stock H4 65/55 watt bulbs with 100/55 watts (boat bulbs in Germany) and with the good glass, they would cut off nicely and not blind people coming the other way. 130 watt H4 bulbs were also possible but needed a relay as the OEM wires were not big enough.

Euro headlights were light years better (npi) than our domestic headlights with the huge reflectors and lots of clear glass. Not as big of a difference today.

LED headlights produce quite a bit of heat, enough that they have tiny fans build in the base. If the fan fails, the bulb fails shortly after. My HIDs don't get that warm but the bulb is constructed in a much different way.

Pierce

With the projector headlight the height actually works to your advantage because the light beam is actually aimed/tilted lower and because the upper half of the light is covered in the low beam use it prevents the useless waisted light blinding oncoming traffic and when off-roading or in the snow the particulates are not reflecting light back at you. The projectors can be perfectly  tuned and the lamp housing mounting them in is unimportant if the lens are clear and prism free. Only the light that reached the ground in front of you that your trying to see is needed. All the wasted light is a nuisance to both you and oncoming traffic. The original Bronco conversion is Hid, but the key is the projector. The Led2 produce 69,000+cd. They are 6K kelvin and I personally would prefer 4-5K
Scott

Agree on that. I just see better at night at 4 to 5K, 6K is too blue and the light/dark contrast is harder for me.

The new headlight buckets with the clear lens do look GREAT! Not a bad price for two either.

Pierce

FWIW, I just did a full housing/turn signal/side reflector swap on my 91 ranger with this one-piece kit: For 1989-1992 Ford Ranger Black Housing 1-Piece LED HeadLights+Bumper+Corner... (https://www.ebay.com/itm/For-1989-1992-Ford-Ranger-Black-Housing-1-Piece-LED-HeadLights-Bumper-Corner/303163991051?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649)

Combined with LasFit 9004 LED headlamps Amazon.com: LASFIT 9004/HB1 LED Headlight Kits-Flip COB Chips-60W 7600LM... (https://www.amazon.com/gp/product/B01H8VILDQ/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1)
And Antline Switchback marker/turn signals Amazon.com: ANTLINE Extremely Bright 3157 3057 3155 3457 4157 Switchback LED... (https://www.amazon.com/gp/product/B07KWNWZW6/ref=ppx_yo_dt_b_asin_title_o06_s00?ie=UTF8&psc=1) and am incredibly happy with how it all looks together and the dramatically increased visibility.

The housing swap required removal of the stock headlight buckets (while retaining the bucket mounting plates) but -in spite of having no instructions- was actually remarkably painless. Total to swap everything (including proper aim of the new reflectors) took about 2 hours from start to finish.
Not sure if the Bronco takes the same housing assembly but boy it looks close; worth looking at if you're looking for an upgraded look/visibility without getting into too much time spent.

 Only the light that reached the ground in front of you that your trying to see is needed. All the wasted light is a nuisance to both you and oncoming traffic. 
Scott
[/quote]
I live in a rural Missouri the land of narrow shoulder-less roads, steep hills and sharp turns and critters big and small. The big critters; deer, cattle, and horses can do real damage. I like to see well into the places where the shoulders are supposed be, and as far ahead as mother nature and the law's of physics will allow, and I know how to use the dim-it switch.
I'm planning to install auxiliary lighting to meet my rural driving needs.

Tim

Tim I agree 100% I've been real focused on stating the low beam is extremely focused and yes it does illuminate to the sides way better than any reflector I've used. Brilliant light that doesn't offend oncoming traffic.Projection headlights produce exceptional focused low beam operation. When you use the high beam the light door is opened allowing light to be higher/elevated. The first Hid projectors I put in the bronco have outstanding focused low beam lights and Brilliant hi beam. Really nice for backroads looking for deer eyes. I wish every one knew how to dim down for oncoming traffic, but with any of these replacement bulbs plug in to your reflector lens assembly you will produce unfocused light in the eyes of oncoming traffic. These are not cheap by any means but they are a real tool. $500 is a lot for lights that really work proper. 5k$ for pretty lights that don't work well is crazy. $40 dollar bulbs that are bright but unfocused aren't for me.
Function over form for me. IMO
Scott

YES,  Utility!

Reading this with interest.  I installed Morimoto HID units in original headlight location a few years back.  Didn't reuse the buckets, they were installed on a flat infill panel.  While bright, the low location produced too many distracting shadows, just the road surface pebbles cast long shadows.  Maybe just me but couldn't stand it.

Reinstalled same lights in the upper panel in a fashion similar to current conversions.  Much improved headlight function.  One consideration ( all four lamps are lit whether on hi beam or lo)  is probably a good idea to use original wiring only for triggering a relay and the hi-lo flip shield in the projectors.  Found  powering all on simultaneously produced a voltage sag that would occasionally throw a transmission snake eyes fault.

I have one of  the passenger side  fixtures biased towards the shoulder  It's a great aid in deer country though sometimes miss the state of ignorant bliss.  Who'd a known there were that many of those motorcycle huntin suicide vermin out there?

Light quality wise....these projectors have far less output  than current car models. They have been trouble/fail free for 8 years or so. I'm hoping to replace them with LED projectors in the near future.  Looking forward to hearing DSD's experience with em. 

Chuck,.
Please give us Pic's of the installed lamps....

Tim...... :D

Another aftermarket Bronco headlight conversion popped up on eBay.  This one has DRLs built into the turn signal and headlight housings.  Different.  Woody.

Black *LED C-BAR DRL* Headlight+Amber Corner Signal for 87-91 Bronco/F150/F25... (https://www.ebay.com/itm/Black-LED-C-BAR-DRL-Headlight-Amber-Corner-Signal-for-87-91-Bronco-F150-F250/333509983598?fits=Year%3A1987%7CModel%3ABronco%7CMake%3AFord&hash=item4da6be7d6e:g:QYQAAOSwpbheQEqt)

I like the idea of this product!  A great way to modernize the old lights while keeping the retro look.  Thanks for sharing this.

I wonder if the low position of the headlights would still be a problem with these?

In my opinion yes, you just can't get any distance without aiming them higher and that interferes with oncoming traffic. I wouldn't have paid for the conversion for cosmetic reasons. I had the same lights on my '96 Monaco Sig. and tried everything on it. They weren't quite as low as the Foretravel, but close.

Tim, sorry I haven't updated, still in the box. Ran into a snafu with the correct plugs to hook the projectors up with. They are in my possession now but haven't gave them a try yet. Will try to make time tonight if possible. The eBay link takes you to halogen bulbs with LED parking lights. I'm not looking for bling, I want performance. Also no light output or spread information shown.  Craneman is correct in that the light spread as focused poorly without projectors cannot be controlled and is thus rejected because I don't want to look at oncoming traffic using them. The projectors cut the light above what you can use to control light spread. Any illuminated light above the ground IMO is actually counterproductive. I don't want to see the dust or snow above the ground level. I've tried and disliked most lights. In my off-road car I only want to see what's ahead of me with zero light leakage on the car. All the light shinning in oncoming drivers eye bothers me. It's also wasted illumination. 
Scott

I put led bulbs in the Bronco lights and they are working great. I do a lot of night driving so I have to have good lights. When I drove
this rig home, I could hardly see unless I was on high beam and now I fined high beam isn't much better.

Not clear on what you are saying here. You put LEDs in the Bronco buckets and they are working great? So why is the high beam not much better if they are working great? How are the headlight lenses?

I'm not trying to be a jerk.

Pierce

As you wish,

Shared album - Chuck Pearson - Google Photos (https://photos.app.goo.gl/xuJqqA8UfGYSFiHy8)

New Bronco lenses were put in before I got the coach I didn't change the high beam only lights. I went with 4M LED bulbs. A few years ago my son noticed the truckers with LED lights weren't putting on their high beams and now I no why. I need great lights as I drive on a very winding dark road to get to Whistler. I think I read somewhere that the Led bulbs don't improve the high beams much so
I didn't buy them for the high beam only.

Too bad I hadn't seen this before my conversion Chuck, looks nice and would have night driving capabilities.

So I finally fired up one of the new LED projector lamps I purchased Black Friday. The first photos were taken 20 feet ahead of the light. There is almost perfect light beam control. The Led only operates at one setting and a curtain drops down to cut off all the light above the beam in low beam. Hi beam is produced by fully uncovering the Led. Second pictures were taken 210 feet down my drive way. On low beam walking back to the led I could see the light but could easily walk without having direct light in my eyes. With the Hi beam there was NO possible way to look and walk. Had to shade my eyes. Can't wait to install.

20 feet low beam. five feet above ground. Hi beam unbearable to take photo

210 feet

210 feet facing Led at five feet above ground low and high beam comparison.

210 feet low beam hand is high beam

Low beam and high beam viewing out 210 feet to driveway base. Single light assembly illuminated. two to be installed

This is a direct replacement ?

This is a projector Led2 assembly installed into a modified aftermarket 1991 Ford headlight assembly.  No fiberglass or paint work required,  but these hi performance led2s are about $350 and the cost of new light assemblies. So their not a $38 dollar led bulb upgrade. The $38 dollar upgrade will be brighter than your stock bulbs but will be unfocused, blinding to oncoming traffic and will never compare in regards to focus or meet DOT requirments.

Ok.. but do they directly fit our GV? Is the 350 for the pair?
Are they glass?
Even if each, that is far less than any other altertive

In this link are some videos that may increase options.
1. Led headlight conversion. Make sure to look at his written comments. He list all parts and explains.
For owners with Izusu tail lights. The rear lights may intrest you.
Mark

https://www.youtube.com/playlist?list=PLq1-J1YKxmjp66YeqjqFFLdJ3rqwCyPQp


Link is now added. Severe operator error on my end. There are 2 parts to headlight mod. Yes its Sob. The idea and method can be used on any unit.  I for one do not have money for "extreme". So I am always looking for information. This author is really doing quality work.  If your thinking about solar. Look at his panel install. About 7 videos.

Sorry to bend this thread

Revised links
Bi-LED: Morimoto M LED 2.0 (https://www.theretrofitsource.com/bi-led-morimoto-m-led-2-headlight-projectors-P-M-LED2?quantity=1) Amazon.com: Pair OE Style Black Housing Amber Side Headlight Corner Lamp for... (https://www.amazon.com/Style-Housing-Headlight-Corner-Bronco/dp/B0821WMFB4/ref=pd_day0_hl_263_1/132-2508346-1747528?ie=UTF8&tag=foreforums-20&linkCode=as2&camp=1789&creative=390957)
Led2 $350
Lens $154
This is for both sides
Scott

I like the LED projector option and updated appearance with DRL's, but not sure I'm tactile enough any longer to attend to all the fiddly bits and am 100% certain that any aftermarket buckets made in China are overpriced junk and not worth the wasted effort.  This is the kit I'm ordering as soon as I finish my tax return. 
Aussie Headlight swap (https://cpaddict.com/bricknose-australian-headlight-conversion-kit/)
I'll put heated JWSpeaker 5x7's in 'em.  Woody. 

Amazon.com: JW SPEAKER 0554461 12-24V DOT/ECE LED RHT High & Low Beam Heated... (https://www.amazon.com/JW-Speaker-Headlight-Single-Chrome/dp/B0784PRXJM/ref=sr_1_8?gclid=Cj0KCQiAnL7yBRD3ARIsAJp_oLaemrkjxSbv9s2z3ZB9WYJyCMdh_OiUHriRRz7dGCbaFVoZ4k-FQE4aAjV3EALw_wcB&hvadid=232531193180&hvdev=t&hvlocphy=9030800&hvnetw=g&hvqmt=e&hvrand=15517343835659878651&hvtargid=aud-837686656069%3Akwd-335198478845&hydadcr=7467_9322228&keywords=jw+speaker+5x7&qid=1582312493&sr=8-8)

Aussie Headlight swap (https://cpaddict.com/bricknose-australian-headlight-conversion-kit/)
Headlights look real good $277 x2 =544 will have to look up the actual performance numbers and patterns
Headlight bucket conversion $386 plus shipping? So at that point your at $940 minimum. If the lights work and don't blind oncoming traffic on low beams that's sounds like a home run. Bonus they are heated for severe winter use. LEDs don't run hot enough to clear ice. Function over Form. I like it.
Scott

LED Headlights - Model 8900 Evolution 2

Scott, they're the ones.  Thanks for all your ingenuity and efforts in the projector mods....didn't intend to steal your thunder. 

I did put JWSpeaker 7" rounds on my jeep...they are simply the best out there and worth every penny IMO...plus made in 'merica.

haha no thunder to be had. I am looking forward to comparing them in person. Again function over form.
The older I get the better everything else has to work for me. I agree 100% on the plastic lens. But I am committed to the Projectors since I own them.
Scott

Here's a few photoshopped pix of what the CPAddict Aussie mod might look like.  Not your average Foretravel.  The quads would be overkill, so I'll most likely go singles and put an amber marker light bulb in the inner Bronco lens or just leave it inert.  Whaddaya all think?  Woody.

Thinking those look pretty good for a simple retrofit, probably hard to beat.  They are, however, still mounted too low for optimal performance. 

It's all good reading, but I just went for the Chrome LED C-BAR DRL Headlight (https://www.ebay.com/itm/233490501620) .  Looks good so far, I have not seen them at night.

Pat,

So the
Chrome *LED C-BAR DRL* Headlight+Amber Corner Signal for 87-91 Bronco/F150/F2... (https://www.ebay.com/itm/233490501620)
Is a Halogen headlight with Led daytime running lights. Very pretty. No illumination information. Plan to purchase replacement Halogen lamps to carry with you. Sounds like your happy with their daytime operation, will they be wired to utilize the daytime operation function? Would like to get some night time operation feedback.
Scott

Pat, do you have LED bulbs in em? Please update with pix as to how these illuminate at night...cut-off line, glare, etc.  Woody.

I do have LED bulbs.  They are 9004 HB1 LED Headlight 4-Sided Bulbs High&Low Beam 2000W 240000LM 6000K White (https://www.ebay.com/itm/223464192929?ul_noapp=true)  You have to buy 2 1157A turn signal light bulbs.  I did have a problem with the plastic ring that holds the 9004 in the headlight assy.  The little fan on the back of the 9004 is too big to use the lock ring.  The headlights came with studs to hold light assy. in MH, I had to unscrew them and use my original screws.  You also have to take an adjustment assy. off the old(2 screws) and install on new headlight assy.  I run with my headlights on, but the new headlights come with the "C-BAR" light wires just hanging loose, you can wire them any way you want.  I connected "C-BAR" with the amber 1157a running lights in the turn signal.  I will get some pics at night soon.  I did keep the old  Halogen  bulbs and can change them out anytime just like changeing any bulb, just unplug.

This is a few pics tonight and about 100' from my MH bay in the barn.  First pic is on dim lights, second is high beam lights(notice the extra light close to the MH and on the ground.  One pic I am outside in front(you can see my shadow) looking at the barn. One shot looking at MH from barn at 100'.

I am sure if I like the new 9004 bulbs.  They have 4 leds, on low beam only 2 light up and they are not across from each other.  The 2 leds that light up on low beam are at 3 oclock and 6 oclock, high beam adds the other 2 leds.  I will have to drive with them.  They have not had any adjustment done.

Pat

Pat. i completely understand how difficult it is to show photos of lights with our level of photography. While in the low beam position if viewing the at the lights from several hundred feet do they produce acceptable unblinding light to oncoming traffic. I want to see and well, but do not want oncoming traffic to be blinded and always flashing me to dim my lights with them in dim position. I've been unable to do this with reflectors and add on led bulbs. The Projectors are a completely different story. Picture don't do them justice. Zero direct light to oncoming traffic. Will have too, would like too, do a side by side comparison sometime
Scott

Hi Scott,
  Due to other problems, I cannot test on the road yet.  I will test on the road soon and show those pics.

Pat,

These look great!!!!  I had thought about trying to manufacture a bezel for mouting 5x7's into the stock housing after I did a home-made conversion.  I am thrilled with my performance with 5x7 glass housings, but I suspect DSD's performance trumps these with his projector mods.

Here are some details on my install for those DIYers:

Headlights differences for 2000 U320's (https://www.foreforums.com/index.php?topic=35577.0)

Next upgrade is a relay and dedicated power to relay & headlights to decrease voltage drop through the headlight circuit.