Headlamp Upgrade

[Melensdad]

I'm sure this may sound obvious to most of you, but it was far from obvious to me. I wanted to keep my original Snow Trac headlamps, but the interior reflectors were very badly corroded and effectively useless. The net effect is that my original headlamps put out about as much useful light as a candle.

I purchased a set of very high quality PIAA headlamps (complete assemblies) and was going to swap them, but then I got a lead on New-Old-Stock original headlamps so I never made the change over. That deal fell apart and I got busy so the PIAA headlamps sat in the box uninstalled for a couple week.

A few days ago I got an email from "Snowcat Operations" that he would sell me his original headlamps. I was again interested, and figured the PIAAs would become my suplimental lights that I wanted to add to the roof rack. Upon investigation, "S-O" realized his headlamps had the original enclosures, but had Hella H4 conversion interiors.

So I went shopping to a few auto parts stores locally and found a set of H4 conversion fixtures (mine are not Hella brand) After dinner last night I went out to see if they would fit. I popped out the original lens and reflector and did a test fit of the new lens/reflector unit and it was ALMOST a perfect fit. Due to a slight difference in the shape of the edge of the lens, the fit is near perfect but not quite. It will require a bead of silicone caulk to make the fit perfect.

The light output from the new set up is about 10x brighter than what I had

I suspect that if you have 'good' reflectors, a swap over to an H4 type conversion will increase your light output by a wide margin, certainly not what I gained. But remember, my reflectors were totally rusted over so they did nothing to reflect any light through the lens.

I really wanted to keep the look of the original headlamps to maintain the originality of my Snow Trac. The H4 assemblies let me keep the original look but it provides modern interior components for practicality.

I still have to finish the install, last night was just the test fit. I'll need to crimp some connectors onto the wires, repaint the headlamp assemblies, etc. But I'll at least be able to see at night when it is done!

 

[Melensdad]

So I went shopping to a few auto parts stores locally and found a set of H4 conversion fixtures (mine are not Hella brand) After dinner last night I went out to see if they would fit. I popped out the original lens and reflector and did a test fit of the new lens/reflector unit and it was ALMOST a perfect fit. Due to a slight difference in the shape of the edge of the lens, the fit is near perfect but not quite. It will require a bead of silicone caulk to make the fit perfect.

A good thing happened today. I WAS WRONG

What I wrote before about needed to remove the original lens proved to be completely wrong, and that is a very good thing. While I could have removed the lens, and siliconed in the new one, I was able to actually able to keep the old glass lens in place, and place the entire new reflector assembly into the rear housing, place the cover over the new reflector assembly and it is IMPOSSIBLE to tell that the inside of the original headlamps has been replaced with modern components.

From the exterior the headlamps look 100% completely original because they are.

 

[Snowcat Operations]

Very cool! Nothing like a nice set of head lights.

 

[Melensdad]

Very cool! Nothing like a nice set of head lights.

Yup, the H4 conversion is a wonderful thing inside the stock headlamps. I get the functionality of a modern headlight but the original look of the antique housings.

I won't have it done until summer, but the roof rack will hold 2 dual bulb PIAA headlights. I'm a big fan of Hella and PIAA, I consider both to be the highest quality headlamps made today. I went with PIAA because they offered a very close approximation of the original headlamp assembly with dual beams. So the combination of function and looks made them my choice. I think the combination of the new headlamp elements, plus the roof mounted PIAAs will effectively light up the night sky in front of my Snow Trac.

 

[Junkman]

Where do you find snow in the summer??????

 

[Melensdad]

I drove my Snow Trac this summer on the grass fields and don't need snow to play with my toy! I intend to drive it on the grass this summer too. In fact I'm considering modifying my track cleats to decrease grass traction (increase slippage) so the Snow Trac drives better on short grass.

 

[Jim_S]

Bob, found some vintage lights for your snow trac.


Jim

http://www.lehmans.com/shopping/product/detailmain.jsp?itemID=4889&itemType=PRODUCT&iMainCat=669&iSubCat=683&iProductID=4889

 

[Melensdad]

I finally got around to downloading the images from my cameraphone of the headlamp upgrade.

This was a very simple project. Pretty much just plug & play.

Photo #1 shows the new reflector assembly. It is sold without a bulb. A standard automotive H4 Halogen locks in place of the reflector assembly from the rear.

Photo #2 shows the orignal light assembly and the reflectors from both of the headlamps. You can see how badly these are corroded. The headlamp assemblies will both be completely restored this summer, but really all they need is a little surface clean up and some fresh paint.

 

[Melensdad]

In the next two photos you can see the installation of the new assembly.

The new reflector sits perfectly inside the original housing. It was nothing more than an amazing stroke of luck that it fit so well.

In the final photo you can see the headlamp reassembled with the orignal lens in place. It is impossible to tell the difference between the orignal components and the new upgrade by looking at the headlamp. UNTIL YOU TURN THE LIGHTS ON. Trying to see ahead of the Snow Trac with the orignal bulbs/corroded refelctors was about as easy as holding a candle up in front of you while driving a car. The new bulbs/assemblies are as bright as any modern car's headlamps. A phenominal improvement.

 

[Snowcat Operations]

BOB it looks great! A vast improvement I bet. My lights are now working again. I also modified the holes going into the engine compartment and head lamp assembly They were drilled out to 5/8" and fitted with rubber groments with 1/2" holes. I used wire loom covering that now goes into the headlamp and engine compartment. No danger of any rub wear. I have another set up I will be doing to make all of the outside wiring bullet proof but will show that when I start to do it.

 

[Melensdad]

I also modified the holes going into the engine compartment and head lamp assembly They were drilled out to 5/8" and fitted with rubber groments with 1/2" holes. I used wire loom covering that now goes into the headlamp and engine compartment. No danger of any rub wear.

Mike, just in case you can't tell

It is alot easier for us to learn from each other when we post photos!

 

[BigAl]

In the next two photos you can see the installation of the new assembly.

The new reflector sits perfectly inside the original housing. It was nothing more than an amazing stroke of luck that it fit so well.

In the final photo you can see the headlamp reassembled with the orignal lens in place. It is impossible to tell the difference between the orignal components and the new upgrade by looking at the headlamp. UNTIL YOU TURN THE LIGHTS ON. Trying to see ahead of the Snow Trac with the orignal bulbs/corroded refelctors was about as easy as holding a candle up in front of you while driving a car. The new bulbs/assemblies are as bright as any modern car's headlamps. A phenominal improvement.

Man !That looks great Bob . I got to try and do something better than I got on my KT7 . The Kristi company just inserted a headlight bulb in the fiberglass and secured it with a couple of screws and washers on the inside so it could not fall out . Seems like the heat alone should have caught the whole damn thing on fire . I don't know it this is the way they did it on a KT3, but on the KT4 Kristi used regular headlight housing and finish chrome rings
Al