Bronco headlight projection conversion

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Bronco headlight projection conversion

December 01, 2019, 02:04:42 pm

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 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... $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...
I'll try to document better.

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Re: Bronco headlight projection conversion

Reply #1 – December 01, 2019, 04:39:18 pm

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.

Re: Bronco headlight projection conversion

Reply #2 – December 01, 2019, 04:58:45 pm

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

Re: Bronco headlight projection conversion

Reply #3 – January 20, 2020, 03:17:31 pm

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...

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Re: Bronco headlight projection conversion

Reply #4 – January 20, 2020, 04:06:09 pm

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

Re: Bronco headlight projection conversion

Reply #5 – January 20, 2020, 08:51:26 pm

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...
Scott

Re: Bronco headlight projection conversion

Reply #6 – January 20, 2020, 11:12:19 pm

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

Re: Bronco headlight projection conversion

Reply #7 – January 21, 2020, 11:18:44 am

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

Re: Bronco headlight projection conversion

Reply #8 – January 21, 2020, 12:19:37 pm

Quote from: dsd – January 21, 2020, 11:18:44 am

They are 6K kelvin and I personally would prefer 4-5K

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

Re: Bronco headlight projection conversion

Reply #9 – January 21, 2020, 02:12:41 pm

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...

Combined with LasFit 9004 LED headlamps Amazon.com: LASFIT 9004/HB1 LED Headlight Kits-Flip COB Chips-60W 7600LM...
And Antline Switchback marker/turn signals Amazon.com: ANTLINE Extremely Bright 3157 3057 3155 3457 4157 Switchback LED... 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.

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Re: Bronco headlight projection conversion

Reply #10 – January 21, 2020, 05:47:08 pm

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

Re: Bronco headlight projection conversion

Reply #11 – January 21, 2020, 09:32:30 pm

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

Re: Bronco headlight projection conversion

Reply #12 – January 22, 2020, 01:23:22 am

Quote from: dsd – January 21, 2020, 09:32:30 pm

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!

Re: Bronco headlight projection conversion

Reply #13 – January 22, 2020, 09:24:21 am

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.

Re: Bronco headlight projection conversion

Reply #14 – January 22, 2020, 08:08:40 pm

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

Tim......

Re: Bronco headlight projection conversion

Reply #15 – February 18, 2020, 12:44:26 pm

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...

Re: Bronco headlight projection conversion

Reply #16 – February 18, 2020, 02:29:54 pm

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?

Re: Bronco headlight projection conversion

Reply #17 – February 18, 2020, 02:36:18 pm

Quote from: bogeygolfer – February 18, 2020, 02:29:54 pm

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.

Re: Bronco headlight projection conversion

Reply #18 – February 18, 2020, 03:06:29 pm

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

Re: Bronco headlight projection conversion

Reply #19 – February 18, 2020, 03:31:10 pm

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.

Re: Bronco headlight projection conversion

Reply #20 – February 18, 2020, 07:06:25 pm

Quote from: oldguy – February 18, 2020, 03:31:10 pm

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

Re: Bronco headlight projection conversion

Reply #21 – February 18, 2020, 08:31:14 pm

Quote from: TGordon – January 22, 2020, 08:08:40 pm

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

Tim......

As you wish,

Shared album - Chuck Pearson - Google Photos

Re: Bronco headlight projection conversion

Reply #22 – February 18, 2020, 09:08:24 pm

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.

Re: Bronco headlight projection conversion

Reply #23 – February 18, 2020, 09:10:50 pm

Quote from: Chuck Pearson – February 18, 2020, 08:31:14 pm

As you wish,

Shared album - Chuck Pearson - Google Photos

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

Re: Bronco headlight projection conversion

Reply #24 – February 18, 2020, 10:47:48 pm

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.

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