Sport headlight conversion - Page 2

KKRRSS · 09-28-2008, 11:59 PM

I spray painted after cutting out the metal to prevent rust. I used a 4.5" grinder, and a sawzall with a metal blade; then touched it up with a die grinder with a grinding stone.

KKRRSS

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1996 Dodge Ram 2500 HD, 4x4 Laramie Club Cab SLT, 5.9 Cummins Turbo, Fuel Slide, BD Performance Torqloc, Pacbrake Exhaust Brake, and 4" Exhaust system.

Kevron · 09-29-2008, 12:20 AM

Quote:

Originally Posted by KKRRSS

Here is a pic of the enlarged holes; the metal headlight housing rear has holes in it already so you can access the bulbs to replace them.

Because the std setup has 1 headlamp, the two headlamp sport headlight assembly needs two access holes at the rear. It's easier just to enlarge the ones that are already there into one giant hole.

yeah makes sense. thats pretty much what i was thinking in my head... looks good, lemme know how it turns out. ill write down where u got ur stuff and ill contemplate doing all this.

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01 24Valve 2500 QC LB, Silver, 2in lift, and DPPI 275RV Injectors, Power Pro Programmer.

Kevron · 09-29-2008, 12:22 AM

Quote:

Originally Posted by KKRRSS

I purchased 94-01 sport headlights from an ebay seller ($200 with shipping).

I purchased (from suvlights.com) a wiring harness with relays to give more power to the headlights and convert from single headlights on each side to dual (sport) headlights on each side ($165 plus shipping).

I purchased new headlight bulbs 2 ea 9004 and 2 ea 9007 of Sylvania's Ultra white, $49 each pair so $100 total.

I also purchased a new headlight switch ($74 plus shipping) and changed it out since my old one was erratic.

I've installed the new switch.
I've removed the old headlights.
I've cut out the headlight bezels to make room for the sport dual-bulb setup.
Now I'm waiting on the suvlights.com relay harness to instal and then instal the headlight housings and then reconnect the battery and enjoy upgraded light at night!

KKRRSS

so was this harness from suvlights.com, a OEM fitted harness? like can u just unplug ur singles headlight harness and plug this one in and away u go?

__________________
01 24Valve 2500 QC LB, Silver, 2in lift, and DPPI 275RV Injectors, Power Pro Programmer.

KKRRSS · 09-29-2008, 12:48 AM

Nope, stock harness has one headlight plug on each side of the truck AND all the power goes through the switch (not relayed). The SUVlights part is relayed (power directly through battery which = brighter lights and cooler switch on the dash) AND has two headlight plugs on each side of the truck for the "sport" headlights.

The sport headlights, new bulbs, and the harness are pivotal pieces needed for the conversion; the switch is because mine was acting up.

KKRRSS

__________________
1996 Dodge Ram 2500 HD, 4x4 Laramie Club Cab SLT, 5.9 Cummins Turbo, Fuel Slide, BD Performance Torqloc, Pacbrake Exhaust Brake, and 4" Exhaust system.

Kevron · 09-29-2008, 01:08 AM

yeah well i was talking about the OEM sport 2 headlight harness. is the suvlight.com harness like the oem dodge stock sport 2 headlight harness? or is there cutting and soldering involved?

__________________
01 24Valve 2500 QC LB, Silver, 2in lift, and DPPI 275RV Injectors, Power Pro Programmer.

KKRRSS · 09-29-2008, 02:08 AM

Don't know; but the suvlights harness is plug and play; it also has relays which is a bonus over either stock configuration.

__________________
1996 Dodge Ram 2500 HD, 4x4 Laramie Club Cab SLT, 5.9 Cummins Turbo, Fuel Slide, BD Performance Torqloc, Pacbrake Exhaust Brake, and 4" Exhaust system.

Kevron · 09-29-2008, 02:29 AM

Quote:

Originally Posted by KKRRSS

Don't know; but the suvlights harness is plug and play; it also has relays which is a bonus over either stock configuration.

sweet okay thanks.:thumbsup

__________________
01 24Valve 2500 QC LB, Silver, 2in lift, and DPPI 275RV Injectors, Power Pro Programmer.

Charlie.Smith · 10-02-2008, 11:54 PM

I've done this in my '96. It is almost the single best improvement I've done to this truck.

You can cut the headlight buckets with an air operated sawzall, doesn't have to be nearly as much as the pictures above. I'll include a picture or two.

The SUVlights harness is expensive, and he took a long time to deliver - but it's worth it. It is very well made and runs everything from relays. It makes the wiring conversion a piece of cake.

You will love the results.

Attached Images

	Opening_cut_larger_a.jpg (31.3 KB, 85 views)
	Cut_from_back_side_a.jpg (31.2 KB, 80 views)

__________________
Charlie Smith - Columbus, Ohio
'97 2500 4x4 auto, Suncoast TC/VB, #5 16.5*, Arrowcraft DRW, Aerotanks D60, KDP
'96 3500 2x4 auto, Goerend TC/VB, #5 16* DDP2 355hp/970tq, D60 tank, KDP

Last edited by Charlie.Smith : 10-02-2008 at 11:57 PM. Reason: Added information.

Kevron · 10-02-2008, 11:57 PM

maybe if i take some time off from school and have some extra spending money ill do this. i added driving lights to my bumper just so i can see! these damn stock headlights kinda suck! juuuuuuuuuust a lil!

__________________
01 24Valve 2500 QC LB, Silver, 2in lift, and DPPI 275RV Injectors, Power Pro Programmer.

DavidB · 02-25-2009, 12:36 PM

Has anyone tried just splicing another set of HL plugs into the harness to power the 2nd pair of bulbs?

__________________
Pics - modded '95 4x4

http://s142.photobucket.com/albums/r...ymore/95Dodge/

KKRRSS · 02-25-2009, 06:52 PM

That would increase the load without decreasing the resistance = bad news for the stock harness.

The stock harness was engineered to carry the minimum required load when it was brand new.

You add age to the harness, and now it's not performing.

You could add more load (2nd set of lights) but it would be (IMHO) too much for your dash switch and the stock harness.

Not a good idea.

Part of the beauty of the harness upgrade is larger wires, direct pull from the batteries, and less load in the switch.

KRS

__________________
1996 Dodge Ram 2500 HD, 4x4 Laramie Club Cab SLT, 5.9 Cummins Turbo, Fuel Slide, BD Performance Torqloc, Pacbrake Exhaust Brake, and 4" Exhaust system.

KKRRSS · 02-25-2009, 07:03 PM

Kevron, you ever do it?

I upgraded my wife's car with a similar harness (from the same guy) and it made a world of difference.

KRS

__________________
1996 Dodge Ram 2500 HD, 4x4 Laramie Club Cab SLT, 5.9 Cummins Turbo, Fuel Slide, BD Performance Torqloc, Pacbrake Exhaust Brake, and 4" Exhaust system.

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09-28-2008, 11:59 PM	#13 (permalink)
KKRRSS Cummins Fan Join Date: Sep 2008 Location: SE Arizona Posts: 98 Thanks: 1 Thanked 2 Times in 2 Posts KKRRSS's Truck Pics	I spray painted after cutting out the metal to prevent rust. I used a 4.5" grinder, and a sawzall with a metal blade; then touched it up with a die grinder with a grinding stone. KKRRSS __________________ 1996 Dodge Ram 2500 HD, 4x4 Laramie Club Cab SLT, 5.9 Cummins Turbo, Fuel Slide, BD Performance Torqloc, Pacbrake Exhaust Brake, and 4" Exhaust system.

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09-29-2008, 12:48 AM	#16 (permalink)
KKRRSS Cummins Fan Join Date: Sep 2008 Location: SE Arizona Posts: 98 Thanks: 1 Thanked 2 Times in 2 Posts KKRRSS's Truck Pics	Nope, stock harness has one headlight plug on each side of the truck AND all the power goes through the switch (not relayed). The SUVlights part is relayed (power directly through battery which = brighter lights and cooler switch on the dash) AND has two headlight plugs on each side of the truck for the "sport" headlights. The sport headlights, new bulbs, and the harness are pivotal pieces needed for the conversion; the switch is because mine was acting up. KKRRSS __________________ 1996 Dodge Ram 2500 HD, 4x4 Laramie Club Cab SLT, 5.9 Cummins Turbo, Fuel Slide, BD Performance Torqloc, Pacbrake Exhaust Brake, and 4" Exhaust system.

09-29-2008, 01:08 AM	#17 (permalink)
Kevron Cummins Enthusiast Join Date: Jun 2007 Location: Juneau, AK Posts: 244 Thanks: 0 Thanked 0 Times in 0 Posts Kevron's Truck Pics	yeah well i was talking about the OEM sport 2 headlight harness. is the suvlight.com harness like the oem dodge stock sport 2 headlight harness? or is there cutting and soldering involved? __________________ 01 24Valve 2500 QC LB, Silver, 2in lift, and DPPI 275RV Injectors, Power Pro Programmer.

09-29-2008, 02:08 AM	#18 (permalink)
KKRRSS Cummins Fan Join Date: Sep 2008 Location: SE Arizona Posts: 98 Thanks: 1 Thanked 2 Times in 2 Posts KKRRSS's Truck Pics	Don't know; but the suvlights harness is plug and play; it also has relays which is a bonus over either stock configuration. __________________ 1996 Dodge Ram 2500 HD, 4x4 Laramie Club Cab SLT, 5.9 Cummins Turbo, Fuel Slide, BD Performance Torqloc, Pacbrake Exhaust Brake, and 4" Exhaust system.

10-02-2008, 11:57 PM	#21 (permalink)
Kevron Cummins Enthusiast Join Date: Jun 2007 Location: Juneau, AK Posts: 244 Thanks: 0 Thanked 0 Times in 0 Posts Kevron's Truck Pics	maybe if i take some time off from school and have some extra spending money ill do this. i added driving lights to my bumper just so i can see! these damn stock headlights kinda suck! juuuuuuuuuust a lil! __________________ 01 24Valve 2500 QC LB, Silver, 2in lift, and DPPI 275RV Injectors, Power Pro Programmer.

02-25-2009, 12:36 PM	#22 (permalink)
DavidB Cummins Fan Join Date: Mar 2008 Posts: 92 Thanks: 1 Thanked 0 Times in 0 Posts DavidB's Truck Pics	Has anyone tried just splicing another set of HL plugs into the harness to power the 2nd pair of bulbs? __________________ Pics - modded '95 4x4 http://s142.photobucket.com/albums/r...ymore/95Dodge/

02-25-2009, 06:52 PM	#23 (permalink)
KKRRSS Cummins Fan Join Date: Sep 2008 Location: SE Arizona Posts: 98 Thanks: 1 Thanked 2 Times in 2 Posts KKRRSS's Truck Pics	That would increase the load without decreasing the resistance = bad news for the stock harness. The stock harness was engineered to carry the minimum required load when it was brand new. You add age to the harness, and now it's not performing. You could add more load (2nd set of lights) but it would be (IMHO) too much for your dash switch and the stock harness. Not a good idea. Part of the beauty of the harness upgrade is larger wires, direct pull from the batteries, and less load in the switch. KRS __________________ 1996 Dodge Ram 2500 HD, 4x4 Laramie Club Cab SLT, 5.9 Cummins Turbo, Fuel Slide, BD Performance Torqloc, Pacbrake Exhaust Brake, and 4" Exhaust system.

02-25-2009, 07:03 PM	#24 (permalink)
KKRRSS Cummins Fan Join Date: Sep 2008 Location: SE Arizona Posts: 98 Thanks: 1 Thanked 2 Times in 2 Posts KKRRSS's Truck Pics	Kevron, you ever do it? I upgraded my wife's car with a similar harness (from the same guy) and it made a world of difference. KRS __________________ 1996 Dodge Ram 2500 HD, 4x4 Laramie Club Cab SLT, 5.9 Cummins Turbo, Fuel Slide, BD Performance Torqloc, Pacbrake Exhaust Brake, and 4" Exhaust system.