Mark 3 Headlamp conversion
Discussion
It's my turn to sort this.
I have, the hole already cut out, the perspex and fibreglass inner.
At the moment I have some 2" Bi LED which will need some form of 3d printed shroud to cover the gap between lamp unit and cowl.
Has everyone gone body colour for the shroud or just black?
For reference, this is the starting point.
And a mock up of the headlight unit with drl/indicator ring. The indicator may be moved to the normal spot
I have, the hole already cut out, the perspex and fibreglass inner.
At the moment I have some 2" Bi LED which will need some form of 3d printed shroud to cover the gap between lamp unit and cowl.
Has everyone gone body colour for the shroud or just black?
For reference, this is the starting point.
And a mock up of the headlight unit with drl/indicator ring. The indicator may be moved to the normal spot
As part of my rebuild, I'm looking into the possibility of changing the headlights from the OE setup to LED.
I would be looking to change the entire headlamp unit, ie. binning the reflector, cover and bulb - to replace with a single integrated unit...
I see many references online to the recent MOT changes making retrofitting LED bulbs into halogen reflectors illegal, as apparently they can't be E-marked.
Does anyone know where the law stands now with replacing the existing reflector/cover/bulb arrangement with a dedicated replacement LED set-up where all the above items are integrated into a single unit?
This kind of thing (image selected to show type of self-contained headlights being referred-to, not specifically this model):
I would be looking to change the entire headlamp unit, ie. binning the reflector, cover and bulb - to replace with a single integrated unit...
I see many references online to the recent MOT changes making retrofitting LED bulbs into halogen reflectors illegal, as apparently they can't be E-marked.
Does anyone know where the law stands now with replacing the existing reflector/cover/bulb arrangement with a dedicated replacement LED set-up where all the above items are integrated into a single unit?
This kind of thing (image selected to show type of self-contained headlights being referred-to, not specifically this model):
The rules are here:
https://www.gov.uk/guidance/mot-inspection-manual-...
"Existing halogen headlamp units on vehicles first used on or after 1 April 1986 must not be converted to be used with high intensity discharge (HID) or light emitting diode (LED) bulbs. If such a conversion has been done, you must fail the headlamp for light source and lamp not compatible.
This does not refer to complete replacement headlamp units which may be constructed with HID or LED light sources.
If a complete headlamp unit has been replaced with a unit that was manufactured with HID or LED light sources, it must not be failed for ‘Light source and lamp not compatible’ but it must meet all other requirements detailed in section 4 of this manual specific to the type fitted at the time of test."
You will need a self-levelling system, which may not have to work!
"Vehicles with high intensity discharge (HID) or LED dipped beam headlamps may be fitted with a suspension or headlamp self-levelling system. If these systems have been fitted, they must work.
Sometimes it is not easy to determine if the self-levelling systems work. In such cases you should give the benefit of the doubt."
https://www.gov.uk/guidance/mot-inspection-manual-...
"Existing halogen headlamp units on vehicles first used on or after 1 April 1986 must not be converted to be used with high intensity discharge (HID) or light emitting diode (LED) bulbs. If such a conversion has been done, you must fail the headlamp for light source and lamp not compatible.
This does not refer to complete replacement headlamp units which may be constructed with HID or LED light sources.
If a complete headlamp unit has been replaced with a unit that was manufactured with HID or LED light sources, it must not be failed for ‘Light source and lamp not compatible’ but it must meet all other requirements detailed in section 4 of this manual specific to the type fitted at the time of test."
You will need a self-levelling system, which may not have to work!
"Vehicles with high intensity discharge (HID) or LED dipped beam headlamps may be fitted with a suspension or headlamp self-levelling system. If these systems have been fitted, they must work.
Sometimes it is not easy to determine if the self-levelling systems work. In such cases you should give the benefit of the doubt."
Bowks - Sorry if I have confused you. There parts in inverted commas are taken straight from the MOT guidance. The parts not in inverted commas are my own comments. The MOT guidance uses MUST. I used MAY. They did not.
There is no grey area. As you say, you cannot put LED bulbs in a unit that was originally designed for halogen bulbs. If you replace the whole headlight unit with one that was designed for LED bulbs, then that is accepted, PROVIDING THAT you also fit a self-levelling system.
The guidance then says that the self-levelling system is part of the MOT checks to be carried out. The guidance goes on to say that it can be difficult to determine whether the self-levelling system works, (you may have driven some cars that do a self-test when you switch the headlights on. They move the beam to the lowest setting and then back up to the correct level, but a lot don't do that, so how can a tester tell whether the self-levelling is working) where that is the case, then the benefit of the doubt is to be allowed, i.e. the test is passed.
My point was that the rules say that you have to fit a self-levelling system, but you might get away with it not working, because how can the tester test it, and because of that, the rules say that he has to give you the benefit of the doubt, and pass the test.
There is no grey area. As you say, you cannot put LED bulbs in a unit that was originally designed for halogen bulbs. If you replace the whole headlight unit with one that was designed for LED bulbs, then that is accepted, PROVIDING THAT you also fit a self-levelling system.
The guidance then says that the self-levelling system is part of the MOT checks to be carried out. The guidance goes on to say that it can be difficult to determine whether the self-levelling system works, (you may have driven some cars that do a self-test when you switch the headlights on. They move the beam to the lowest setting and then back up to the correct level, but a lot don't do that, so how can a tester tell whether the self-levelling is working) where that is the case, then the benefit of the doubt is to be allowed, i.e. the test is passed.
My point was that the rules say that you have to fit a self-levelling system, but you might get away with it not working, because how can the tester test it, and because of that, the rules say that he has to give you the benefit of the doubt, and pass the test.
You will need a friendly MOT tester if you want to fit hid or led, they're supposed to have a wash system installed. I don't think many people with a tvr are deluded enough to take their car to the main DVSA place, hand over the keys, sit in reception ignoring everyone and expect a pass though 
s p a c e m a n said:
You will need a friendly MOT tester if you want to fit hid or led, they're supposed to have a wash system installed. I don't think many people with a tvr are deluded enough to take their car to the main DVSA place, hand over the keys, sit in reception ignoring everyone and expect a pass though
Yet our Fiesta ST has LED headlamps from the factory and no wash system...A bit of morning reading on gov.uk:
"4.1.4. Compliance with requirements
If a complete headlamp unit has been replaced with a unit that was manufactured with HID or LED light sources, it must not be failed for ‘Light source and lamp not compatible’ but it must meet all other requirements detailed in section 4 of this manual specific to the type fitted at the time of test."
"4.1.5. Levelling devices
Vehicles with high intensity discharge (HID) or LED dipped beam headlamps may be fitted with a suspension or headlamp self-levelling system. If these systems have been fitted, they must work."
"4.1.6. Headlamp cleaning devices
You must inspect vehicles first used on or after 1 September 2009 equipped with headlamp washers."
"4.1.4. Compliance with requirements
If a complete headlamp unit has been replaced with a unit that was manufactured with HID or LED light sources, it must not be failed for ‘Light source and lamp not compatible’ but it must meet all other requirements detailed in section 4 of this manual specific to the type fitted at the time of test."
"4.1.5. Levelling devices
Vehicles with high intensity discharge (HID) or LED dipped beam headlamps may be fitted with a suspension or headlamp self-levelling system. If these systems have been fitted, they must work."
"4.1.6. Headlamp cleaning devices
You must inspect vehicles first used on or after 1 September 2009 equipped with headlamp washers."
Bowks said:
It's my turn to sort this.
I have, the hole already cut out, the perspex and fibreglass inner.
At the moment I have some 2" Bi LED which will need some form of 3d printed shroud to cover the gap between lamp unit and cowl.
Has everyone gone body colour for the shroud or just black?
For reference, this is the starting point.
And a mock up of the headlight unit with drl/indicator ring. The indicator may be moved to the normal spot
Bowks did you finish this conversion successfully? If so where did you get the diy kit from?I have, the hole already cut out, the perspex and fibreglass inner.
At the moment I have some 2" Bi LED which will need some form of 3d printed shroud to cover the gap between lamp unit and cowl.
Has everyone gone body colour for the shroud or just black?
For reference, this is the starting point.
And a mock up of the headlight unit with drl/indicator ring. The indicator may be moved to the normal spot
Cheers
Yes I did. This won't be for everyone and it's not cheap.
The lights are from retrofitsource. Morimoto 2" bi-led plus a relay to make it work between hi/lo beam. Add to that a pair of DRL/turn signals. The gap between the headlight unit and the 7" hole was 3d printed and then machined from aluminium and anodised. There is a 3d printed casing behind to keep it all dry. I didn't do any of this, clever people did, but I did choose the items and this create the challenge. From a distance they look like big menacing black holes.
An alternative would be a pair of 7" led headlamp like the ones the land rover lot use. I just wanted to try something different.
The lights are from retrofitsource. Morimoto 2" bi-led plus a relay to make it work between hi/lo beam. Add to that a pair of DRL/turn signals. The gap between the headlight unit and the 7" hole was 3d printed and then machined from aluminium and anodised. There is a 3d printed casing behind to keep it all dry. I didn't do any of this, clever people did, but I did choose the items and this create the challenge. From a distance they look like big menacing black holes.
An alternative would be a pair of 7" led headlamp like the ones the land rover lot use. I just wanted to try something different.
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