The amount of time that is going into these custom headlights is just staggering. [Mcole254] is working on his brother’s truck, replacing the stock headlights with High-Intensity Discharge (HID) lamps and rolling some nice LED features into the mix while he’s at it.
The build starts by removing and disassembling the stock headlight assembly. In order to get the enclosure apart he heated it in the oven until the glue was softened and the parts could be pried apart. The goal is to replace the reflectors with an assembly that suits the new lamps and LEDs. Above you can see the white pieces which were vacuum formed from a mold that [Mcole254] made from wood and PVC. He tried several iterations using his home-made vacuum former but couldn’t get the definition he really wanted. The most recent posts from him show some massive 3D printed parts that will be used instead.
While inside he added a line of amber LEDs for the turn signal. You can seem them mounted along the silver strip between the upper and lower reflectors. A demo of those super bright additions is embedded after the break.