I have a non-HID Knightsports headlight kit and I'm going to try and fabricate a Hella 90mm low beam projector to replace the low beam headlight that came with the kit. Pictures to follow. I know going to a sleek kit would be easier and possibly cheaper, but I'm not ready to part with my pop-ups just yet. Plus IMO the Knightsports kit is super awesome looking.

 

Sub for this! I would also like to try it

 

I did a test fit last night, and there are several cosmetic things that will need to be changed:

The stopper that prevents the headlights from raising to stock height will need to be moved.
The Hella lights will need to be trimmed slightly to fit in the KS headlight bracket.
A bracket for the Hella lights wil need to be made to mount in the KS bracket.
The hellas are slightly smaller than the headlight surround some somthing will need to be made to fill the space so is less likely to get in.

 

Depend on space, you should be able to use something better than the 90mm projector.

 

From my test fit, there basically zero room already, and I don't want to modify the KS bracket. Hella's 90MM should be more than enough, I'm just wondering how the heck I'm going to mount it. I have several ideas but I need to play around with it first. I'll post pics tonight to show you what I mean.

 

Here is the KS bracket


Here is the bracket installed with the lights that came with the kit.


If you notice in the picture below, the arm that extends just behind the lower headlight, that stops the headlights from reaching stock height and will need to be relocated to accommodate for the longer projector housing.




Here they are closed

 

Yeah, that's not a lot of room, the Hella will be a tight fit too.

 

From eyeballing the fit, the bulb plug in the hella will rest where the stopper arm rests on the KS bracket.

 

Update:

After a lot of cutting and moving I got it to fit and turn on, next up is permanent mounting.

 

Subscribed

 

Nice job. The Hella's will work much much better.

 

Currently the Hellas are being held in by two screws tapped into the casing. Its actually mounted sturdier than I had imagined. Plus its easy to adjust up and down.

 

Looks good

 

Thanks, but now the other side.

 

Which Hella lights are you using? part number?

Looks great!

 

If looks are everything then this fabrication is going to look good and work. The issue is the mounting situation. The hella low beam projectors are too long to fit in the bracket so there was significant cutting involved and when actually mounting the light to the bracket there is nothing currently on the market that would even come close to help the lights fit nicely into the bracket. I've tried pipe clamps and some other things. The best bet is put a pipe clamp on the light itself and drill to retaining screws in the clamp to keep the light in place. My idea with the clamp and screw is similar to the IFP lights that come with the kit, granted it doesn't look the best but it works and you won't see the crazy mounting job with the light shroud and cover on. In my opinion this mod is a one off. There is now way this could be implemented into a project kit for the Knightsports headlight kit, as you have to cut the actually lights and then reseal them with....sealant. Anyways I'll keep this thread updated and should have some more pics soon.