Round-Eye Lighting Upgrade
 

Hey, gang. After two close calls with deer on I-80 through the Poconos last week, it’s apparent that the ‘78 Suburban could use a light upgrade. Forward and to the sides. Mom and Dad gifted me a pair of KC Daylighters for my birthday (I’m 41... and I still get awesome surprise gifts for my birthday from amazing parents), but they aren’t street legal. 200,000 candles. Each. Thought about trying to make them legal, but that seems like an exercise in frustration.

So to make things a little clearer at night, I’m looking at a few other options. I’ve already done relays, so we’re set there. I’d like to keep things as close to mid-70s in appearance as possible. And no blue light. Gives me a headache as a driver. Seriously. Anyway...

1. Auxiliary SAE/DOT/ECE driving lights. Hella 550s or similar mounted on the bumper. Four lights are better than two, right?

2. Upgrade the mystery sealed beams to SilverStars. Or another “premium” sealed beam. Will I see legit improvements?

3. Hella H4 conversation housings with something like 55/100w bulbs. Hella’s glass lenses looks pretty ‘authentic’.

4. A combination of 1 and either 2 or 3. Obviously better than any of the others alone.

5. Figure out a lens, reflector, bulb combo for the Daylighters that will be street legal. Or close to it. Ha.

Appreciate your opinions. And because every thread needs a photo...

Re: Round-Eye Lighting Upgrade
 

I have found that halogen lights work pretty well if properly aimed. That truck is old enough it could have OEM plain incandescent. Halogens are a definite improvement over plain bulbs.

Please, make one of your tests to put someone else in your truck and both of you drive toward each other on a two lane road at 65 or so mph. If you find yourself cussing that idiot with the blinding headlights, you have more work to do on your new lighting solution. It doesn't improve safety much if you are turning that oncoming 5000lb vehicle into an unguided missile with a closing speed of ~130mph that will hopefully pass about 6 feet to your left.

Re: Round-Eye Lighting Upgrade
 

Thanks, Parrot. I’ll have to check again, but I believe they are Halogen sealed beams. One is a Wagner, other I can’t find a name on. No telling how old they are. I’m not interested in LEDs or HIDs.

Please trust me when I say I won’t leave the driveway until I’m 100% sure the bulbs are aimed safely and correctly. The guys running Cummins Rams around home are on a lighting kick that ranges from obnoxious to friggin dangerous. Lots of big rigs on the interstate seem to be in a contest to see who can light up the world the brightest, other drivers be damned.

Now I gotta put on my shoes and go out in the rain because it’s bothering me that I don’t remember if I saw ‘halogen’ on my sealed beams. Be back directly...

Re: Round-Eye Lighting Upgrade
 

The halogen round headlights on my 76 GMC are brighter than any other vehicle in my driveway. If I was upgrading lights it would be on one of my newer vehicles.

Re: Round-Eye Lighting Upgrade
 

Rainy night here on the Delaware River, but I had to go look. The sealed beams are a Wagner 2D and an AC Power Beam Guide. They seem to have the same output. Not sure on the Wagner, but I’d guess the Power Beam isn’t halogen. Neither is marked ‘halogen’. Both are aimed properly. Even with relays, they leave a lot to be desired. Especially on rainy nights.

Al, what part of Maine are you in? I’ve spent a bit of time there over the years. Deer, bear, moose... all make poor speed bumps. What fer halogens are you running? Relays? Are SilverStars considered top of the line for a sealed beam?

A pair of Sylvania SilverStars is ~$50 at Advance. Looks like Hella H4 housings and decent bulbs will be double that. Figure $100+ for good halogen auxiliary driving lights. Hella, KC, PIAA, etc. I’m willing to pay to see, but I’m with you both. I think a halogen solution - or combination of solutions - is right for me rather than LEDs or HIDs. Especially considering the cost.

Re: Round-Eye Lighting Upgrade
 

Best thing I can think of is to add relays into the light wiring harness. I used a kit I got thru LMC and it did more to increase the brightness of the lights than just changing to another style bulbs. I am back to running Sylvania sealed beams.

https://www.lmctruck.com/1973-91-che...dlight-harness

Re: Round-Eye Lighting Upgrade
 

Thanks, Bill. Relays was one of the first upgrades I did. It helped a bit, but I need a bit more light to feel safe at night.

Re: Round-Eye Lighting Upgrade
 

Check Rockauto for prices on sealed beams. I bought four 7" halogens that turned out to be NAPA branded Wagner for less than $4 each!

Re: Round-Eye Lighting Upgrade
 

I'm way up north in moose country. My halogens are General Electric; if there is any difference in brands I don't know. My 94 Buick and 96 Acura and 03 Cadillac and 02 Jeep don't have lights as bright as my old GMC.

Re: Round-Eye Lighting Upgrade
 

This makes a big difference especially with upgraded bulbs like halogens.

Lights dim because the switch causes resistance, and a thus a voltage loss. With relays you get a full 12V to them. So if the engine is running is closer to 14V.

Re: Round-Eye Lighting Upgrade
 

I would start with this as well.

Re: Round-Eye Lighting Upgrade
 

Already got relays. :)

Re: Round-Eye Lighting Upgrade
 

If you want to try something other than sealed beams, try a pair of Jeep Wrangler headlamps. They are bolt-ins and can use a variety of replacement bulbs available at any auto parts store. Wiring is straight-forward and it helps that you already have a relay system installed in your truck. I put them in my truck and lighting was notably improved

Re: Round-Eye Lighting Upgrade
 

7 inch led replacements are going to be dot approved and really bright. also wont look out of place and use hardly any juice.

Re: Round-Eye Lighting Upgrade
 

Re: Round-Eye Lighting Upgrade
 

https://www.google.com/shopping/prod...Ccg4UBDzAgjSAw

those are led and look bone stock for example

Re: Round-Eye Lighting Upgrade
 

Lee - your truck looks great. Wrangler headlamps are a definite consideration. Basically the same idea as the Hella lenses with H4 bulbs. Are yours halogen or LED? They look pretty good for a modern headlamp in an old truck.

Is there much difference in light quality between the SilverStars and a housing/H4 bulb solution?

Nekkid - those Deltas do look darn stock. The Truck-Lites not so much. I wonder if there would be room between the battery and the back of that Delta with the LED bulb... Any first hand experience with those?

Re: Round-Eye Lighting Upgrade
 

I run Phillips 9008vp bulbs

Re: Round-Eye Lighting Upgrade
 

I think I'm going to go down the path of installing the Hella or other (Jeep, those Deltas, etc.) 7" H4 conversion lens/bucket. That will give me options for a variety of H4 halogen or LED lamps to try. Even something like 55/100w high watt halogens. I'd be $50+ into 'good' SilverStar sealed beams and might not see that big of an improvement... so it makes sense, to me at least, to go another step and do the H4 conversion.

I'd give LEDs a shot, but extremely bright, white/blue light triggers migraines for me. One of my offices went to 'daylight' LED lighting and its a real strain for me to work there. Goal is to find a lamp/lens combo that gives me good distance but especially lights up the edges. Maybe driving lights are still in order down the road...

My relay setup could be improved too. I cut the harness and right now it uses the stock Hi/Low wires to trigger the relays. Relays are powered with 12g directly from the post on the alternator. 14g grounds from the relays to radiator support. Then the stock harness wire from relays to the headlamp connectors and between the headlamp connectors. Stock harness ground wire from the headlamp connectors.

If I go to 12g from the relays to headlamp connector, 12g between driver side and passenger side headlamp connectors, and ground the headlamps with 12g, I should see an even better result. Everything is clean and well done, but I think the skinny stock wire that remains in the power circuit from the relays to lights is a limiting factor. I really should get the multimeter out and reconfirm that I have 14.2v at the headlight connections...

Re: Round-Eye Lighting Upgrade
 

Thanks for the link.
I was just thinking about doing this upgrade when I came across this thread.
I just ordered this kit. I was gonna build a harness, but I've got 100 projects.
Spend the $$, and take an hour to install it when it gets here. right?
Maybe it will actually get done now. We'll see if the relays are enough, or not. Either way, it should be a good step in the right direction.


Keep us posted on the lighting upgrade. I'm interested to hear how it turns out.
-Russ

Re: Round-Eye Lighting Upgrade
 

The KCs use the same bulb size as the no longer made Per Lux 200T that every 18 wheeler ran back in the 70s-80s. The size is called PAR 36 for 36 1/8s wide or 4.5". I run the amber bulbs out of the NAPA/Wagner catalog #4415A. They come in different colors and wattage and beam patterns for anything from an ambulance to landscape lighting. 4456 is a motorcycle headlamp with high and low beam that could be wired in combo.
https://store.fmmotorparts.com/fmstorefront/

Re: Round-Eye Lighting Upgrade
 

Russ, I’ll keep everyone posted on this upgrade. That’s what this site is about!

Farmall - You’re got my interest, however my Daylighters are a 6” light, Spot (long distance) lens running an H-3 100w bulb. It’s crossed my mind that swapping to Spread lenses with a 55w bulb may get me close to DOT compliant. At least close enough to not blind other drivers or get a ticket.

Here are the lenses.
https://www.kchilites.com/replacemen...g-kc-4205.html

And the 100w bulbs that I’d swap for 55w.
https://www.kchilites.com/replacemen...n-kc-2767.html

Thoughts? KC does make a DOT compliant LED Daylighter ($$$), but I’d like to stay halogen if possible.

R

Re: Round-Eye Lighting Upgrade
 

I'm miles from home so I can't measure mine. The next size up is 5.75" or PAR 46 which is what a 70 Vette would have for headlights. You can get them in fog, or hi-low.

Re: Round-Eye Lighting Upgrade
 

I've been down this road before as well... All your possible solutions are well thought out and definite solid options. It seems your priorities are:

1. Keep stock appearance
2. Remain legal/safe
3. No blue LED light
4. Relatively affordable

I had a Toyota FJ60 a few years back, which has the same headlights as our Squarebodies. I ended up doing a Hella sealed beam conversion with upgraded wiring, relays etc, and was happy with the results. However, for the money spent, the improvement was marginal. Even with the BEST sealed beam setup you're still talking 60+ year old technology... higher power draw for less light. I hate to say it, but I'm in the LED camp. The light output, longevity of the bulb and reduced power consumption is just a no-brainer when you compare.

Now, keeping your priorities in mind, looking stock is a must. The Delta lights are a new one on me, but they look pretty close to stock, could be worth a look. My pick is these from Dapper Lighting, who are nearby in my area and have a good reputation.

https://www.dapperlighting.com/colle...k/products/oe7

The other issues are the light color, and the headache problem. Can't help ya there, if it gives you migraines, it aint worth the trouble...

Cost: the LED's are a bit more pricey, but the Hella conversions with all the wiring, bulbs and relays aren't exactly free either... and consider the fact that the LED's will probably outlast the steel the truck's built out of, it'll make up the cost difference in the end.

All in all, it's up to you, but I think Buy once, Cry once, go for the best you can get and stay legal.

Another good thread on lighting... from the FJ60 crowd.

https://forum.ih8mud.com/threads/bes...t-2016.963214/

Re: Round-Eye Lighting Upgrade
 

Yep. You got what I’m driving for, pal. And... aaaarrgggghhhh!!!! Timing!! I read your post right after the Big Brown Truck delivered the Hella conversions. Aaarrrggghhh!! Those Dappers look great! But the harsh white/blue is a real issue for me. If someone gets behind me with intense blue-white headlights for any length of time I gotta pull over and let them pass because a migraine will start. So maybe it’s for the best. But man, I like everything else about those lights. I may need to give them a shot anyway...

Thanks for chiming in. Sweet Pea is still an inspiration.

Re: Round-Eye Lighting Upgrade
 

My Hella H4 conversion made a massive difference.

Before:
https://i.imgur.com/B6gGJfCl.jpg

After:
https://i.imgur.com/3DNKutxl.jpg

Before:
https://i.imgur.com/d4QhLKbl.jpg

After:
https://i.imgur.com/Ha64N9gl.jpg


Yeah, I had some aiming issues before (my adjuster screw wont stay put in the bucket so the light falls to the ground) but those issues persisted with the H4's and the difference is still remarkable. Quite a bit brighter and with better cut off than my 2009 Honda... and thats without the relay kit and with the bulbs the H4 kit comes with.


I'll probably still do some aux lighting down the road - most likely two driving, two floods... because Maine has a ton of large deer, including the moose kind. That said, I am super happy with the H4 upgrade - probably the biggest bang for the buck improvement that I've done so far... that wasn't my LS swap.

Re: Round-Eye Lighting Upgrade
 

Lights look great. Are they the DOT or E-code Hellas? I have everything organized and hope to put mine in this afternoon if the freezing rain stops!

Re: Round-Eye Lighting Upgrade
 

You will not be disappointed with the Hella H4 Conversion headlights. From an outward daytime appearance perspective, the Hella H4 conversion looks almost stock during the day but the surface of the glass lens is less convex- almost flat when compared to the sealed beam headlight. You can see the silver reflector inside the lens- if you're really looking for those details.

Silverstar Sealed beam headlights had a short lifespan for me before converting to Hell H4. I went through four Silverstar headlights in a vehicle I only drive occasionally before finally calling it quits on them. Silverstars did not improve lighting output or beam pattern but only changed the color hue.

Hella H4 Conversion
($77.87)
https://www.amazon.com/gp/aw/d/B001G...?ie=UTF8&psc=1

Headlight H4 Headlamp Light Bulb Ceramic Socket Plugs Relay Wiring Harness Kit
($18.95)
https://www.amazon.com/gp/aw/d/B06XH...?ie=UTF8&psc=1

After two years of using the H4 Halogens, eventually I swapped them out for LEDs from SuperBrightLEDs.com. They come with blue and yellow tint with so you can adjust with the color temperature if you prefer a blue-white, white or more of a traditional halogen color but with LED light output.
($79.95)

Re: Round-Eye Lighting Upgrade
 

Fantastic write up. Thanks for the input. The LEDs are a direct replacement for the H4 halogen bulbs in the Hella housing? Light quality/pattern just as good?

I have relays installed and have about all the parts and pieces to upgrade a few spots, but I do wish I would have went with something like the harness you posted to avoid the two cuts I had to make to the stock harness...

Weather not improving... might could get these in this afternoon if the freezing rain stops...

Re: Round-Eye Lighting Upgrade
 

The H4 Conversions are E4, so they are European style. The most notable difference in the E4 is a sharp cutoff line when the low beam is on.

Below is a photo that I took after install and initial aiming. I've since aimed the headlights slightly lower to account for the 4" lift on my K5.

I was skeptical of putting LEDs in H4 housings for concern of blinding oncoming drivers. However, the Hella H4 - E4 reflector housing, with a sharp low beam cutoff, works properly with a quality correctly designed LED bulb with diodes located in the same location as tungsten filaments.

Hella H4 E4 Low Beam Fitted with LEDs - no color filter installed - prior adjusting lower
http://67-72chevytrucks.com/vboard/a...1&d=1564045098

Hella H4 E4 High Beam Fitted with LEDs - no filter installed
http://67-72chevytrucks.com/vboard/a...1&d=1564045098

Re: Round-Eye Lighting Upgrade
 

That's a fantastic improvement. Hella good. (see what I did there?) Halogens or LEDs in those last photos?

BTW, your K5 is one of my favorites. Really, very well done.

R

Re: Round-Eye Lighting Upgrade
 

Glad this information is helpful.

The only minor complaint on the light pattern is on high beam. I notice faint crisscross Xs on trees located above the roadway. So faint that it won't show on photos. The light output on high and clarity is still better than anything I've tried. The low beam is flawless though.

The H4 LEDs I posted are a direct replacement for the H4 Halogens in the Hella housing. The only modification required is to remove the rubber seal on the back of the Hella H4 housing where the three prongs from the H4 halogen protrude through the seal. Simply remove the center portion of the seal by cutting the rubber between the prong holes. A sharp utility knife is all you'll need. You'll be left with a hole in the center of the seal about the size of a dime to install between the heatsink and bulb. The H4 LED mentioned in my previous post is designed to rotate for proper beam pattern but this won't be necessary. Conveniently, this design also allows the heatsink to be removed without tools. Then the seal can be installed between the bulb and heatsink. LED bulb and seal can be reassembled and inserted into the Hella H4 housing. The seal works to keep moisture out, as it was originally designed to do. It's almost too simple.

The relay harness from Amazon was a direct fit. Plug and play, no doubt an improvement not matter what your headlight setup is- and best of all, it's cheap at less than $20.

Below is another photo of the Hella H4 Conversion housing. The silver bulb reflector/sheild is more noticeable in this photo. I'm getting used to it and it's a small cosmetic trade off for so much improvement in lighting for not much money when compared to other options.

Re: Round-Eye Lighting Upgrade
 

The photos posted above are with LEDs. You will probably like the halogens that come with the Hella H4 Conversions- I was happy with them. They are a dramatic improvement over the sealed beam headlights.

I was impressed with the Hella H4 halogens in my K5... until purchased a newer F150 that had factory optioned LED headlights. When switching back and forth between vehicles, I realized there was more potential with the lighting on the K5 and decided to do some research and find the correct LEDs.

Let's be honest, these old truck don't stop like new ones. I want as much warning of animals and objects on the road as I can get. The LEDs have help with easily spotting deer now. The reflected light from the eyes of night time creatures is much more intense.



And thank you, I appreciate your compliment on the K5.

Re: Round-Eye Lighting Upgrade
 

^^This. It's a safety thing. The blue/white intense light is an issue for me, but those amber gels might be just the ticket if I go to LEDs. Nifty!

And you're welcome. Easy to compliment a nice rig!

Re: Round-Eye Lighting Upgrade
 

Installed in the freezing rain tonight in the hotel parking lot. Much improved over the sealed beams! Gotta fine-tune the aim a bit... low beams have a definite euro-style cutoff and ‘eyebrow’ up and to the right. High beams are a bright, sort of ‘muddled’ pattern that seems to point back to the left. Curious.... this was while aimed at the wall of the hotel. Highs definitely aim left compared to where the lows point.

On the road the improvement was very noticeable. Gotta perfect the aim, but Hella easily makes good on their claim of 50% brighter lows and 25% on high beam. Pattern and clarity is much better too. Higher output halogen bulbs or LEDs would bring even better improvements.

And other than being quite a bit flatter than sealed beams, they look darn stock.

Hope for some photos tomorrow. I’m pretty happy. Thanks for all the advice.

R

Re: Round-Eye Lighting Upgrade
 

Installing headlights in freezing rain and at a hotel- that's dedication.

Thanks for following up. Glad you're happy with the Hellas. It does take a few attempts to get them dialed in and aimed just right but will be a dramatic improvement.

Agreed, the euro style cut on low beam off does take a little getting used to but diligent use of high beams makes the low beam cut off a non-issue.

I look forward to seeing your photos.

Re: Round-Eye Lighting Upgrade
 

Daytime photos. First with sealed beams. Then with the Hella H4 conversion lenses. Nighttime photos later. You know. When it’s dark. :)

Re: Round-Eye Lighting Upgrade
 

Here’s a neat one from last night in the freezing rain. Hella on passenger side. ‘Power Beam’ sealed beam on driver’s side. Neat!

Re: Round-Eye Lighting Upgrade
 

Looks great! Your headlights have DOT on them whereas mine are E-code. Nice find!

Where did you purchase them from? I'm having a hard time finding those Hella H4 Conversion DOT.

Re: Round-Eye Lighting Upgrade
 

Hella part number 002395301 at Summit.

https://www.summitracing.com/parts/hla-002395301

I also bought ceramic high-temp connectors in the event I'd try +watt H4 halogen bulbs. Something like Philips 55/100 or Osram 80/85s. Good thing. The stock 'tulip'-shaped connector on the harness wouldn't connect to the Hella bulb with the rubber dust boot.

https://www.summitracing.com/parts/r...-994/overview/

Now to finish upgrading the harness and to get the KC Daylighters wired up... Then maybe aux driving lights and/or fogs. Any suggestions on vintage-style driving or fog lights?