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Old Jan-07-17, 11:19 PM   #1
 
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Being a major DIY guy, I've decided to start putting picture-to-post so other people can benefit from my insanity. MY 2008 TBSS has only 50k miles on it and is in great condition (I am the original owner).
So, let this be the first in a series of MadMax's DIY projects.

"THE MADMAX FOG LIGHT MOD" (to allow full size HID bulbs)

So, the party starts when I decided to change out my headlights to Anzo projector/halo style headlight assemblies. I really like these aftermarket lights, and yes, I did install new HID light kits to this kit too:



Here is the link on Amazon for the Anzo lights
https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1




I elected to go with 5,000k spectrum as I like a bright white with few blue or yellow overtones to ruin the clean look of the nice white light.

and, of course, being a detail freak I made sure ALL the light sources matched: Lowbeam Headlights, Halo rings, Highbeam Headlights, and Fog Lights are all in the 5,000k color spectrum. I had no problems with hyper flash on the turn signals (as some people report) so install was very simple and straight forward.

As HID bulbs are not appropriate for high beam applications (ramp up lag time) I went with Xenon halogens but with a clean 5,000k white color for the HIGH beam side of my main headlights:

https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

As for the HID kits, I went with a local supplier here in Huntington Beach CA. (sorry, no links available)



So, now for the fog lights themselves......

As many of you already know, most standard HID bulbs are too long to fit in the factory TBSS housings. To address this, I decided to fabricate EXTENSIONS so as to allow an additional 1/2 length to accommodate the extra bulb length. One complication is the rather high temperatures that the bulbs generate, thus any such material must A) be able to withstand the high temp environment, and B) be relatively whether proof at shedding both rain water and road debris from the fog light housings.

After mulling over possible materials, I found the following items to do quite nicely.
Parts List:
1) one standard 3/4" diameter Copper pipe coupler (available at any HD or Lowes)
2) one appropriate sized bottle screwcap (thicker industrial type)
3) one 3/4" OD O-Ring
4) four 3/4" long stainless steel screws




Step:
1) Cut copper fitting down to approx. 5/8" in length
2) Cut or drill out bottom out of bottle screw cap
3) Ream out threads from inside of screw cap (I used a 3/4" spade bit)





4) Insert copper fitting into cap as shown and then add o-ring. There should be a small taper left of appox. 1/8" or so (this is necessary)




5) Remove 4 stock screws that hold the light bulb retainer plate to back of each housing, save plate for next step




6) Place plate over HID bulb and lock into position
7) Slide newly assembled extension over plate (as shown) and four new screws




8) Screw new mod assembly into factory housing as shown. The "taper" should fit right into the factory fog light housing with the 0-ring providing a reasonable level of water resistance.




9) Hook up the HID ballast and secure all wires very well to frame with zip ties and/or wire retainers so that nothing moves around on you.
.
10) Options:
as heat and vibration are the two main enemies of electrical ballasts, I....
a) sandwiched some high density foam between my ballasts and the vehicle frame rails so as to reduce vibrations, and
b) located ballast in area that should get plenty of air flow to enhance heat dissipation.

All said and done, I am very happy with the result and look forward to my new bright white driving lights:



I hope this helps and please feel free to ask questions.

Kevin T. Adams
Garden Grove, CA
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Last edited by MadMax; Jan-08-17 at 11:29 AM.
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Old Jan-08-17, 04:11 PM   #2

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Are the full size 9006 brighter than the 880 HID ? Just curious why you went through the trouble of putting 9006 bulbs because the 880 HID are plug and play.

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Old Jan-08-17, 05:33 PM   #3
 
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Quote:
Originally Posted by Bushwacker View Post
Are the full size 9006 brighter than the 880 HID ? Just curious why you went through the trouble of putting 9006 bulbs because the 880 HID are plug and play.

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I'm not sure if they are any brighter however I wanted to use the same ballasts as those used on my main driving lights for interchangeability, so this dictated what bulbs were mated to the ballasts when I bought them.. I also wanted the same color spectrum,
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