Halogen Headlight Conversion Kit - Headlight Hop-Up

And because the original reflector is being used, the integrated setup attaches to the headlight bucket just as it was intended to-which also means that unlike the sealed beam conversion, you can now run a fluted glass lens.

Prior to this, one of the reasons it wasn't possible to use a Tilt Ray lens, at least not the ones designed for early Chevys, was due to the bottom portion being flat, not round. Using the old reflector overcomes that obstacle, but you'll need to trim the new reflector a tiny bit in order for the lens to seat correctly.

Before cutting the new reflector, however, position it in the bucket so that the parking light socket is either at the 12 o'clock position (stock), or if you'd prefer to have it below for a blinker, at 6 o'clock (but make sure there are no issues with the alignment notches on the outer edge).

With a little trimming here and there, not only do old and new fit like a glove, you can now install the original-style cork gasket for the lens-just as it was intended. After that has been accomplished, there's nothing else prohibiting the use of the stock glass lens.

When it comes to wiring the halogen headlights, it is possible to use original-style Bakelite plugs. However, in this case, a replacement headlight pigtail from Chevs of the 40's was used with the connector plug included in their halogen conversion.

In order to use the newer headlight plug, just release the existing wires and, using the same style terminals (open-barrel F-type or twin-lock), install on the pigtail loom-but make sure you insert the high/low and ground terminals in their correct slots.

With the halogen conversion handled, all that remains now is installing the Juliano's LED turn signals. The kit comes with detailed instructions-even if you skip the wiring part, make sure and follow the guidelines for mounting, unless you're not concerned with centered, evenly spaced signals.

With a template marked on masking tape, before any holes were drilled, the headlight was mounted on the '39-just in case the center of the bucket wasn't actually "centered", it's better to verify now rather than modify later.

Even though it goes without saying, always use a rubber grommet anywhere wiring passes through metal. And speaking of wires, the pre-soldered ones for the signals won't extend into the radiator support as the headlight loom does-you'll need to accommodate when running the wires from the dash.

Save for the non-stock turn signals, which look more like a Guide or Dietz headlight of the same era, you'd be hard-pressed to tell that these have a halogen conversion kit behind the fluted glass. Maybe one day the poor old buckets will receive some much needed attention too?!

There's definitely no arguing the fact that the old "dipped"-style lamps don't come anywhere near illuminating as brightly as a halogen unit, that's for sure.