Introduction: DIY Sports Car LED Headlights

Picture of DIY Sports Car LED Headlights

So thats my SUV. Beautiful, Is'nt it? Especially with all the decals and Art I've made.
(Did I hear someone requesting an Instructable for such Decals? ha ha)

Notice those big round headlights?
Good to look at, But not good to look With!

Onto the next page...

Step 1: What to Do?

Picture of What to Do?

Am I going to sit here just hoping that I don't hit some boulder in the dark? NO.

I took matters into my hands, and guess what? A Super-Duper Powerful LED Lights for my SUV!

I take no responsibility What-so-ever from Using, making or Putting such lights on your car.
Any Direct or indirect damage arising from making or using such product is Solely YOUR Concern.
Don't catch me if police catches you.

Using Custom lights on road may not be allowed by your laws. Kindly contact the local state regulation/ Police for more details on these. This instructables is made in faith of 'OFF-ROAD' use.

Step 2: Lets Get This Working.

Picture of Lets Get This Working.

I did'nt want too much of power consumption, So halogens are out!

High power LEDs fit in the math perfectly.
I chose Cool white LED for the job. Here are the Specifications-

Color Temperature- 7000 kelvin (cool white)
Max power- 800mA
Forward voltage - 3~3.4V
Package- Star with heatsink.

8 Such LEDs were used. 

Other materials-

8-Degree Acrylic lenses
Aluminum heatsink

Other tools, Silicon,  Wire, Drivers, Drill, Cutters, and more.

Next page please...

Step 3: How to Make LED Module

Picture of How to Make LED Module

First step is to mount the LEDs onto Aluminum heatsink.

This heatsink will wick away the heat from LED emitter, and also serve as a mount for the whole cluster.

Add some thermal paste, and carefully place each LED onto aluminum heatsink.
   The way/ Order if LED will depend upon your electrical configuration, Numbers of LEDs used and your budget. Look at your LED driver's user manual for wiring diagram.

Proceed to Solder the wire once your placement is final.

Step 4: Making It Strong

Picture of Making It Strong

These lights would be exposed to harsh conditions in daily use.... Be it Crater sized Potholes, Dust,  Sweltering heat, rain, And Strong sun. 

I found a simple way to add great strength is to use Silicon.
Silicon is cheap, quick and Long lasting.
take your favorite tube of Silicon and dab away every part and corner of LED.

Make sure everything is working before doing this, and fix your lenses properly.

Click the pictures and look at them in detail.

Step 5: Good to Go!

Picture of Good to Go!

Once you've plastered enough silicon, let it rest for a while. Overnight is a good idea.

Now hunt for a nice place to mount your system.
I mounted it right on my Steel bumper , With some Long nuts and bolts.
They are wired to a separate switch on the dashboard.

Refer to your car's manual for wiring instructions.

Step 6: Pics1 Ahoy!

Picture of Pics1 Ahoy!

Here are the stuff you've been finally waiting for ages.
The comparison Shots! 

Click at each image and save them to your computer. Compare side by side.
Look at Filename for instructions/ Scenario

All shots taken in manual with Same settings in each shot. look at EXIF.

Step 7: Final Shots 2

Picture of Final Shots 2

More pics for comparision....

Click at each image and save them to your computer. Compare side by side.
Look at Filename for instructions/ Scenario

I will add more pics of real off road scenerio after my exams,
Stay Hooked!


Mjtrinihobby (author)2016-06-21

amazing work.

atesta (author)2011-11-04

Hey, love the build and it looks great! I recently got a panel from an LED street light and it has 20 3w cree emmitters on it. I decided to replace my old HID offroad lights with a homemade LED bar like yours. I plan on using all 20, in 5 groups of 4 wired series so they can handle 12v(with a 1ohm 10W resistor in line). My main problem is optics, i tried reflectors for flashlights but the spot is to small, im looking for more flood. What are those lenses you are using? Could you provide a link possibly? Thanks!

bhvm (author)atesta2011-11-06

Please use refrain using Resistors for Power LEDs. Not only they're inefficient, but can also shorten the lifes of LED. LED Forward voltage chages with Temperature, hence you need a Constant current power source.

For the lenses, have you tried Luxeon website? else try Khatrod. you;ll need 8 or 10 degree as per your descriptions. You can also try oval lenses- These are fantastic, beam is less in height but very wide.

ihrishi (author)bhvm2013-10-04

Hi, any idea where can I source the components in India? Specially the lenses?


bhvm (author)ihrishi2013-10-04

if you come bombay, lamington road is the best bet. you can also now buy ready made Led headlights from

mika.ch04 (author)2012-09-22

Excellent work friend.
i also wana make headlight for my hero honda cbz .
can u plz guide me...i wana use 1w 3 led and 5mm led..
plz guide me abt resistance which one 1 use for that


bhvm (author)mika.ch042012-09-22

You shall not use resistances with power LEDs. Please find a suitable DC Driver. Also, i'd suggest you 3W LEDs as the price difference is dismal. You'll need atleast 6 of these 3W LEDs for bright and safe illunination.

rrsasuke24 (author)2011-04-25

Why didnt you like the Safari's headlights?
They are pretty good
How do the LEDs fair on long drives?

bhvm (author)rrsasuke242011-04-25

Safari's Headlights are complete Junk. An SUV of this caliber atleast calls for Xenon Projector HIDs. This vehicle can easily attain speeds of 150+ and hence I brainstormed this LED idea for the sake of safety.
Please do run down from all the comments, you shall recieve all your answers.
Click "view all steps on one page" and read all comments.

rrsasuke24 (author)bhvm2011-04-26


And you're right. They surely are necessary if you are driving at abt 150 at night.

bhvm (author)rrsasuke242011-04-27

Great, So what else? Planning any Mods now? WHich car you have?

rrsasuke24 (author)bhvm2012-05-03

well.. even am not happy with my vehicle's headlights.. so, i am planning to install LEDs. :)
I have an sx4.

Zedone Two (author)2011-11-30

Is this legal? Don't your front lights have to be adjusted to the right angle, and would they act as a high beam, rather than dipped lights?

Otherwise, cool instructable

HeIsCoolMG (author)2011-03-02

Watch out for cops in the US with these extra lights, any additional lighting that isn't approved by the DMV and not part of the original headlights, taillights, turning signal etc. external lighting can get you a ticket

abadfart (author)HeIsCoolMG2011-07-01

they don't seem to mind highway lights on a motorcycle

rrsasuke24 (author)2011-04-25

Where did you get all dat material in India.
Which city?

vanmankline (author)2010-08-15

Did you use any type of current or voltage regulation? If so, what did you use?

Jonesy70 (author)2010-07-21

g'day I love what you have done, works great. I'd like to have a go at making one myself, where can I get all the parts?

bhvm (author)Jonesy702010-07-26

Please search the comments, I've answered it before- Ebay Luxeon Creee Check their websites.

CraigSnedeker (author)2010-04-12

Nice truck!

And yeah, I'd like to know how you make those stickers :P

jordan.longoria (author)2010-03-11

 where can I get lenses like this?

bhvm (author)jordan.longoria2010-03-11




Check their websites.

jmallen (author)2010-03-01

Does anybody know where I can find the 8 degree lenses?

bhvm (author)jmallen2010-03-05

Where do you live? 

jmallen (author)bhvm2010-03-05

Southern Maine, US

bhvm (author)jmallen2010-03-05

I don't live in US.


Jayvis Vineet Gonsalves (author)2010-03-05

I wanted to build LED headlamps for Herohonda Splendor. I am glad that I stumbled on your this instructable. Can you tell me how many lumens does each LED generate and what is the cost of each of them. Where in India do you live and from where did you buy the LEDs and the lense ? Please give me the rates in Rupees.

Hello Vineet,

Its great to see your interest in LED lighting.

LEDs give out about 200~220 Lumens each when driven at 700mA~800mA
So we are talking about a total of 1600~1800 Lumens overall output.
Lets remember that a Bike 35W bulb is 700 Lumens only, you can judge the amount of light you need.
I ordered the LEDs and Lenses from Bombay.

Could you please see me on my yahoo Chat 'bhvm333'
we can discusses further design there. 

Have a nice day.

Sorry but I have no account in yahoo messenger we can also discuss by using private messages of Instructables. I am sending you one. Check your inbox

megapix (author)2010-02-25

Very nice. I didn't realize you could get that much light out of those LED's. You might want to add a strip of clear polycarbonate in front of the lights as extra protection. Although you will lose a little light, you will get extra protection from rocks, and your acrylic lenses will last a lot longer if you don't have to clean them as often.

bhvm (author)megapix2010-03-05

Light output is extreme... Difference is like Night and DAY.
You can actually drive the car with ONLY LEDs running.

I thought of your Acrylic/Plexi suggestion before, but then, Dust went in and settled between the plexi and Lenses........making me have to open the screws to clean this arrangement. Will think of something else now. 

Scott_Tx (author)2010-02-21

Since I dont see any screws I'm guessing you're using thermal epoxy instead of thermal grease.

bhvm (author)Scott_Tx2010-02-21

1>Yeah, Glue and Silicon make them tight and weatherproof.
2>Controllers are inside the Engine compartment.(700mA)
  P.s- your profile pic scared looks scary.

KEep MOre CommenTS cOmInG!! 

Scott_Tx (author)Scott_Tx2010-02-21

Oh yeah, I dont see any current regulation either

About This Instructable




Bio: Necessity is the Mother of Inventions they say, I live in challenging land called INDIA. where the Sub par conditions like power issues, heat, Dust ... More »
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