LED Headlight Upgrade 1995 U320

Topic: LED Headlight Upgrade 1995 U320 (Read 3253 times) previous topic - next topic

LED Headlight Upgrade 1995 U320

June 12, 2020, 08:28:19 am

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...
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
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.

Re: LED Headlight Upgrade 1995 U320

Reply #1 – June 12, 2020, 08:34:51 am

Very tasty! A great looking conversion completed in a non destructive fashion. Nice job.

Re: LED Headlight Upgrade 1995 U320

Reply #2 – June 12, 2020, 08:59:21 am

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!

Re: LED Headlight Upgrade 1995 U320

Reply #3 – June 12, 2020, 09:35:38 am

WOW! Beautiful. When can I get mine done! Ha Ha

Re: LED Headlight Upgrade 1995 U320

Reply #4 – June 12, 2020, 10:15:20 am

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

Re: LED Headlight Upgrade 1995 U320

Reply #5 – June 12, 2020, 10:17:25 am

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.

Re: LED Headlight Upgrade 1995 U320

Reply #6 – June 12, 2020, 10:31:58 am

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.

Re: LED Headlight Upgrade 1995 U320

Reply #7 – June 12, 2020, 10:33:46 am

Quote from: folivier – June 12, 2020, 10:17:25 am

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.

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.

Re: LED Headlight Upgrade 1995 U320

Reply #8 – June 12, 2020, 10:34:32 am

Quote from: folivier – June 12, 2020, 10:17:25 am

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.

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.

Re: LED Headlight Upgrade 1995 U320

Reply #9 – June 12, 2020, 10:37:38 am

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?

Re: LED Headlight Upgrade 1995 U320

Reply #10 – June 12, 2020, 10:44:01 am

That is one of the nicest upgrades I've ever seen. Really well done, DJ!
jor

Re: LED Headlight Upgrade 1995 U320

Reply #11 – June 12, 2020, 10:49:16 am

Quote from: wolfe10 – June 12, 2020, 10:37:38 am

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?

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.

Re: LED Headlight Upgrade 1995 U320

Reply #12 – June 12, 2020, 11:16:19 am

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.

Re: LED Headlight Upgrade 1995 U320

Reply #13 – June 12, 2020, 11:21:42 am

Quote from: oldguy – June 12, 2020, 11:16:19 am

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.

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.

Re: LED Headlight Upgrade 1995 U320

Reply #14 – June 12, 2020, 11:25:53 am

Quote from: D.J. Osborn – June 12, 2020, 10:49:16 am

...probably should have taken some pictures of the sub-assemblies.

Gibbs Rule #17: ALWAYS TAKE PHOTOS

Re: LED Headlight Upgrade 1995 U320

Reply #15 – June 12, 2020, 01:01:02 pm

The backup lights are typically flood lights and should not be used forward facing after dusk. IMO
Scott

Re: LED Headlight Upgrade 1995 U320

Reply #16 – June 12, 2020, 02:16:04 pm

Quote from: dsd – June 12, 2020, 01:01:02 pm

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.

Re: LED Headlight Upgrade 1995 U320

Reply #17 – June 12, 2020, 03:31:16 pm

May be a dumb question, but does this require cutting rectangular hole in front cap for recessing the headlight bucket assembly?

Re: LED Headlight Upgrade 1995 U320

Reply #18 – June 12, 2020, 03:50:02 pm

Quote from: Realmccoy – June 12, 2020, 03:31:16 pm

May be a dumb question, but does this require cutting rectangular hole in front cap for recessing the headlight bucket assembly?

Yes. Holes are required.

Re: LED Headlight Upgrade 1995 U320

Reply #19 – June 12, 2020, 04:08:36 pm

Quote from: D.J. Osborn – June 12, 2020, 03:50:02 pm

Yes.

So # 5 was the only one you couldn't have.
Looks great so not a issue to have to cut the holes.

Re: LED Headlight Upgrade 1995 U320

Reply #20 – June 12, 2020, 04:53:05 pm

Quote from: craneman – June 12, 2020, 04:08:36 pm

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."

Re: LED Headlight Upgrade 1995 U320

Reply #21 – June 12, 2020, 05:36:40 pm

Quote from: Chuck Pearson – June 12, 2020, 08:34:51 am

Very tasty! A great looking conversion completed in a non destructive fashion. Nice job.

I agree.
I'M IMPRESSED!

Re: LED Headlight Upgrade 1995 U320

Reply #22 – June 12, 2020, 06:12:04 pm

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.

Re: LED Headlight Upgrade 1995 U320

Reply #23 – June 12, 2020, 06:16:22 pm

Now that's a keeper!
What was the cost of all the components?

Re: LED Headlight Upgrade 1995 U320

Reply #24 – June 12, 2020, 08:42:12 pm

Quote from: Lon and Cheryl – June 12, 2020, 06:16:22 pm

Now that's a keeper!
What was the cost of all the components?

Total cost was just over $900.

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