Introduction: DIY Sports Car LED Headlights

About: 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 and environmental factors are just tough! and They have force…

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?

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.

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

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

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!

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!

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

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!