OK, here's a basic "how-to" for version 2.0.
1. Remove the red lens cover, and remove the metal heat-shields from the reflector housing.
2. Use a dremel, jigsaw, or hacksaw to cut along the line where the mounting area crosses the bottom side of the reflector housing. Cut up the sides, but DO NOT cut the top off.
3. Mark off the depth of the LED strip when placed at the first cut, and then make your second cut across the bottom of the reflector and up the sides, parallel to the first cut.
4. Join the two cuts and remove the section of reflector from the housing.
5. Using a dremel or file, clean up the edges of the cuts and make any additional clearance necessary so that the LED strips can be slipped into the newly cut out area. **Tip: I left this as a tight fit so that the back of the reflector housing would press against the LED strips and help hold them in position.**
6. Grind or file down the tab grooves on the top of the reflector that held the heat shield in place. This will allow you to push the LED strips all the way up against the reflector housing.
7. Using the dremel tool or file, grind down the little lip that is left over on the bottom of the reflector housing. This will help let the bottom row of LEDs shine wider and clearer.
8. Feed the wires through the back of the housing and position your LED strips in the cut out so that they are centered and tight together in the housing.
9. Mark and drill small holes (1/8") in the mounting area of the housing. One on each side (left and right) directly above and one each directly below the mounting holes for the LED strips.
10. Use 4" zip ties to secure the two LED strips together, and then again to secure the top strip to the top of the mounting area and the bottom strip to the bottom of the mounting area.
If possible, now is a good time to test everything out and make sure it all works as expected. If it's all good, proceed.
11. Use some clear Silicone RTV Adhesive (I prefer the Permatex brand) to run a bead along the edges of the cutout to seal the lamp housing. I also squeezed out some globs around the mounting tabs of the LED strips and the zip ties in order to keep it all secure.
12. Put it somewhere that is well ventilated and let it cure for a couple of days.
13. Mount the assembly in the car and hook up the wires with whatever method you prefer (plug-n-play bulb adapter, wire nut, solder, crimp connector, etc.). Red=Hi(+), Black=Lo(+), White=Ground(-)
Reply With Quote
