I had never been satisfied with the headlights on our 1995 U320. I've generally avoided nighttime driving when possible, but this year's events reminded me that there could be some situations where nighttime driving would be unavoidable. I decided to replace the existing headlights and had several objectives for the project.
(1) I wanted the headlights to be at an optimum mounting height (much higher than the original design that just met the 24" minimum legal height requirement).
(2) I wanted LED lights with a color temperature around 6,500K (about daylight).
(3) I wanted rectangular headlights to continue the rectangular theme of the clearance and identification lights and the original headlights.
(4) I wanted LED Daytime Running Lights (DRL).
(5) I didn't want to cut out any of the original front fiberglass and I wanted to retain a degree of the original styling of the lower front area.
I ordered headlight mounting assemblies designed for Kenworth, Freightliner, etc. trucks on eBay.
I ordered headlights from z-offroad on Amazon. They are made by China DOT SAE Kenworth Led Headlights Truck 4x6 Inch Led Headlights For... (https://www.morsunoffroad.com/other-car-makes/dot-sae-kenworth-led-headlights-truck-4x6.html)
I ordered LED turn signals and DRLs from Partsam on Amazon.
I ordered polished 304-8 stainless steel from Custom Metal Fabrication - Metals Online - Cut2Size Metals (https://www.cut2sizemetals.com)
I added front lower side marker lights/reflectors from Truck-Lite 18050Y and will be replacing the other clearance and identification lights with Truck-Lite 18050Y and 18050R lights .
The DRLs are connected to the "Aux Lights" switch and that circuit is now powered whenever the ignition is on.
I am extremely pleased with the new headlights' performance. They have an excellent pattern that provides bright, white light with good cutoff so that oncoming traffic isn't blinded.
Very tasty! A great looking conversion completed in a non destructive fashion. Nice job.
IMHO a really nice conversion/upgrade! Excellent choice of components, plus professional level installation.
I think your coach now looks much better than the ones converted by FOT/Xtreme (with the little round recessed lights). The rectangular shape of your new lights, and the stainless finish of the trim, really complements the "classic" overall design of the Unicoach front cap.
WELL DONE!
WOW! Beautiful. When can I get mine done! Ha Ha
Very nice installation. Would really like to see a picture of the light pattern against a wall. Did the manufacturer have any light display images, that would also help. I've looked at a lot of these LEDs and most fall short. Hope I can get to see them in action down the road. Again very nice. The stock Ford light reflectors and prism lens are 1980 junk backed with low candle power bulbs.
Scott
Very nice DJ. Can you post how you did the DRL conversion? I'd like to do that to my auxilliary lights so they will come on with the ignition on.
I feel like a six year old in a room full of adults when I see what you guys are capable of. That's a beautiful conversion.
That would be easy to wire: Come off the "ignition hot" side of the ignition solenoid with a wire that will be used to close a 40 amp relay (upsizing relays gives more longevity at little added expense). Always hot/battery side of ignition solenoid to fuse to relay.
Relay to driving lights. When ignition on, the relay closes and sends power automatically to the driving lights. All this at the front of the coach where it will be easy to wire.
Our 1995 has the roof spotlight that is on the ignition circuit & so it was easy to simply move the "Aux Lights" switch wiring to that same source. You should have a wiring diagram that will show a similar source for your coach.
David,
Nice job.
Do you have specs/drawings/work order # for Custom Metal Fabrication for the SS pieces that cover the OE headlight location?
Was it formed or flat and thin enough that you could bend it into place?
How were they secured?
That is one of the nicest upgrades I've ever seen. Really well done, DJ!
jor
I will later post the list of stainless pieces I ordered from cut2sizemetals. The visible panel is 20-gauge 304-8 that came flat & I bent it by hand. I used other thicknesses & other shapes to adapt to the fiberglass brackets to which the original lights were mounted. I don't have drawings & probably should have taken some pictures of the sub-assemblies.
That is an impressive job. Where did you get your driving lights. I can't find any that don't blind the on coming drivers. On my last
coach I had to wire them to go out when I had the headlights on low beam. I wired my driving lights to come on when the parking
brake is released.
They aren't actually driving lights. They are actually surface-mount LED backup lights that I mounted on 304-4 stainless. I ordered them & the other DRLs from Partsam on Amazon.
Gibbs Rule #17: ALWAYS TAKE PHOTOS
The backup lights are typically flood lights and should not be used forward facing after dusk. IMO
Scott
The LED backup lights I used are mounted extremely low and are not bright enough to cause glare for oncoming drivers. They produce a beam that would work acceptably well for backup lights but isn't a high-output flood llight. Their.output is about the same as the DRLs used (on factory-production new Hondas for example) that stay on even when headlights are on.
May be a dumb question, but does this require cutting rectangular hole in front cap for recessing the headlight bucket assembly?
So # 5 was the only one you couldn't have.
Looks great so not a issue to have to cut the holes.
Thanks! Probably should have written something such as "not cut off major sections of the original fiberglass."
I just ordered LED bulbs for my headlights, it's a good thing your post came afterwards or I would be doing a much bigger project. I really like what you've done. You're going to be pestered for details so if you get a chance we would love to have a list of part numbers and the measurements for rough in of the main head light holes.
Now that's a keeper!
What was the cost of all the components?
Total cost was just over $900.
Nice looking upgrade, David. Thanks for sharing.
The 10ga sheets are horizontal and go forward from the fiberglass brackets that held the old headlights. Each upper 10 ga sheet is spaced down from the upper fiberglass bracket by the 1" square tubing. The 1" steel angles are then attached at the front of the 10 ga sheets using 3M VHB tape. The angles are then attached the 20 ga polished steel using the DRL mounting screws. The 3"x 9" polished sheets fill the gaps at the ends of the polished front panels by the generator access door and the 1"x 1"x 9" angles connect them. The other end of each polished front panel is attached to the screws that mount the Truck-Lite side marker light.
The project total cost was just over $900.00
Stainless steel ordered from Custom Metal Fabrication - Metals Online - Cut2Size Metals (https://www.cut2sizemetals.com)
STAINLESS STEEL SHEET 304-8 (Custom Cut)
Thickness: 20 ga.
Size: 9 x 34 1/2 Inches
Qty: 2
STAINLESS STEEL SHEET 304-8 (Custom Cut)
Thickness: 20 ga.
Size: 3 x 9 Inches
Qty: 2
STAINLESS STEEL ANGLE 304 (Custom Cut)
A: 1"
B: 1"
C: 1/8"
Size: 21 Inches
Qty: 4
STAINLESS STEEL ANGLE 304 (Custom Cut)
A: 1"
B: 1"
C: 1/8"
Size: 9 Inches
Qty: 2
STAINLESS STEEL SQUARE TUBING 304 (Custom Cut)
O.D.: 1"
Wall Thickness: .120"
Size: 21 Inches
Qty: 2
STAINLESS STEEL SHEET 304-2B (Custom Cut)
Thickness: 10 ga.
Size: 3 1/2 x 21 Inches
Qty: 2
STAINLESS STEEL SHEET 304-8 (Custom Cut) (To Mount DRLs in Aux Lights Location)
Thickness: 20 ga.
Size: 3 3/4 x 7 3/4 Inches
Qty: 2
The following links show the other lights I ordered:
Amazon.com: Z-OFFROAD 4pcs 60W Rectangular 4x6 Led Headlights Dot Approved... (https://smile.amazon.com/Rectangular-Headlights-Replacement-Freightliner-Oldsmobile/dp/B07ZH7WC53?ref_=ast_sto_dp)
Amazon.com: Partsam 2PCS 17" White 23LED Surface Mount Truck Reverse Backup... (https://smile.amazon.com/gp/product/B01EWOV38C/ref=ppx_yo_dt_b_asin_title_o05_s00?ie=UTF8&psc=1)
Amazon.com: Partsam 2x 6" Oval White Led Trailer Lights 10 LED Clear Lens... (https://smile.amazon.com/gp/product/B01GHU9HBE/ref=ppx_yo_dt_b_asin_title_o08_s00?ie=UTF8&psc=1)
Amazon.com: Partsam 2Pcs 6 Inch Oval Amber Led Trailer Lights Clear Lens... (https://smile.amazon.com/gp/product/B075B537V1/ref=ppx_yo_dt_b_asin_title_o08_s00?ie=UTF8&psc=1)
KD LH Dual Rectangular Headlight Asem with Headlights for Western Star | eBay (https://www.ebay.com/itm/KD-LH-Dual-Rectangular-Headlight-Asem-with-Headlights-for-Western-Star/202711448043?_trkparms=aid%3D111001%26algo%3DREC.SEED%26ao%3D1%26asc%3D20160908105057%26meid%3D7c5a05ae0b3f419f96759ed8cb2007f3%26pid%3D100675%26rk%3D6%26rkt%3D15%26mehot%3Dnone%26sd%3D133402765357%26itm%3D202711448043%26pmt%3D0%26noa%3D1%26pg%3D2380057%26brand%3DKD&_trksid=p2380057.c100675.m4236&_trkparms=pageci%3Ae87147d6-acfe-11ea-bff4-fe36c0464145%7Cparentrq%3Aaab8daf81720ad33ded10e44fff8a38e%7Ciid%3A1)
18 Series, LED, Yellow Rectangular, 3 Diode, Marker Clearance Light, P2, 2... (http://www.truck-lite.com/webapp/wcs/stores/servlet/ProductDisplay?storeId=10001&productId=49303)
I commented on the Foretravel FB Page, but hey 2 times is OK.....Fantastic job, I contacted the metal fab shop you use to see if they can make my new S/S Wet Bay pieces. Thanks for the tip
Let us know what they say about the S/S pieces for the wet bay. I was thinking the same thing when I saw the source. Mine is tore apart right now adding the SeeLevel panel and really wanting to clean it all up first.
LOVE this headlight upgrade. Next on my list.
David, that looks fantastic. I always wanted the Extreme conversion, but I like the looks of that even better. It doesn't hurt that the price is much better also. If my coach doesn't sell, I can see this happening ::)
Larry
Thanks for the idea David. The headlight frames and the bezel came today. Hopefully I will start tomorrow.
I have finished one headlight and the passengers side is all wired and just needs to be installed. I wouldn't
have done this job now except I needed to work on the heat control. Now I just need to get rid of the
old headlights and glass it in.
I finally got the old headlight space glassed in. It is ruffed in and if it warms up enough I will finish smoothening it out. I am using
gel coat for now and next spring when it gets warm enough I will paint it.
Wow that is awesome. I just drove my U320 1995 last week at night and hated it.
May I ask how much all this cost and did you do this by yourself or have it done
Rick Maddox
509-939-0740
rlmlimited@comcast.net
I did all the work myself and for cost I can't remember. What I used was a headlight assembly, headlight bulbs and bezel between
5 and 6 hundred Canadian. The headlights are Kenworth. The maybe a couple hundred for fiberglass and the gelcoat was left
over from painting the roof.
If you want an easy way of upgrading your headlights just look at pictures of my coach. I have two JW speaker LED headlights. There's a thread on it somewhere. The headlights themselves will probably run you about $500 for the pair . They also don't incorporate turn lights so you would have to add those in mind stick out you either like them or hate them I don't mind them at all. Some sheet metal and carriage bolts both stainless to cover the old headlight assemblies, wiring and then you're done so probably about $750 total to $1,000 maximum. And you'll have the best night driving experience you can have in these coaches. There's no way that the Foretravel or Xtreme headlight conversion will match my JW speaker headlights for usability brightness and cost. Of course mine has a funky look to it that you either like or don't. I happen to like the way it looks but it's definitely different than the front of the most class A's.
I've been very comfortable driving at night with these lights both on well it highways as well as really dark, think pitch Black, roads and campgrounds at night.
or you could just do the same thing and not drive at night which is what most people do anyway.
Bob
The biggest reason I did this job now is I needed to repair the heater water temp control switch and the hole to mount
the headlights was perfect to get at the control. I had led bulbs in the Bronco headlights which worked for me but were horrible
for the oncoming drivers.
This is link to Bob's Jwspeaker headlights.
For Tex (Headlight photos) (https://www.foreforums.com/index.php?topic=37827.0)
J.D. upgraded to JWspeaker as well:
Front Facad modifications? (https://www.foreforums.com/index.php?topic=20411.msg151811#msg151811)
I like that a lot!
Congratulations on a great job.
To J D Osborne; that is a great upgrade.
This is a great upgrade to make it look 2020 ish.
The only problem I see is the marker / turn lights are not on the front but on the side. There may be some problems with that in some states.
I finally got out to adjust the lights and see how they work. As you can see they are awesome. The fiber glass work is done and when
it warms up I will give it one more coat of gel coat and see if I can match the color.
So I must ask, in the low beam position can you walk out in front 100m and look back at the coach with acceptable glare as a oncoming car on a two lane road. Depth perception is difficult to capture with the cameras I own at night.
That being said it looks to have a good pattern and spread. Great project and good looking.
Scott
Looks great! You could complete your LED conversion by replacing the incandescent fog lights. I used a pair of Rigid flood lights on our coach. They would provide a great "fill-in" light to complement your headlights, especially in strange camp grounds after dark. Even mounted in the down low position, my LED floods provide more than enough light for driving all by themselves, although the oncoming drivers would probably not appreciate them.
What did you do to your coach today IV (https://www.foreforums.com/index.php?topic=23683.msg215600#msg215600)
Scott they are easy to look at until you get super low and then they are blinding. They are the light Kenworth, Freightliner etc
uses. I had led bulbs in the Bronco headlights before and they were great for me but were blinding to the oncoming drivers.
Chuck I would like to find led driving lights that don't blind the oncoming driver. My driving lights come on when the park brakes are released and my last coach I put in a relay so they wouldn't come on when low beam was on.
DJ Osborn,
Do you have the part number for your led turn signals from Partsam please?
Love your modification...
Peter
Well I finally got to test out the new lights and they are great. Had no trouble seeing and it was a dark rainy night, with lots of
traffic coming toward me with lots of turns.
oldguy...wish I could do fiberglass molding like that!!
I didn't know I could do it until I did it. If it isn't perfect just add another coat and then sand.
^.^d ^.^d ^.^d
P