The victim-ahem-beneficiary of some stealth lighting: My '58 Impala Sport coupe. This car is a daily driver, and in the wet and dark Northwest, good lighting is a must. Immediately after obtaining this car seven years ago, I swapped out the old dim T3 low and high beam lights for the more contemporary H4 halogen headlights.
They put out quite a bit more candle power, but the flat glass lens and modern fluting doesn't look right on this car. So what is a hot rodder to do in pursuit of traditional looks but with a need for bright and safe lights? Solution: Install the T3 lenses on the H4 halogen reflectors.
Though not a direct conversion per se (actual halogen conversion kits do exist), the swap is rather straightforward, and the results speak for themselves by providing a better lit road when you're behind the wheel.
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1 I bought these nice T3...
lights.jpg)
1 I bought these nice T3 lights at a swap meet. The single filament high beam version is the most common, and they are usually cheaper.
2 The fluting is virtually...
2 The fluting is virtually the same on the high and low beam lens, so you can let the restorers enjoy the low beam versions. Or better yet, find burnt out low beams.
3 Probably the safest method...
3 Probably the safest method to remove the lens from the housing is to use a regular metal cutting disc with a bench grinder. You'll want to use a respirator mask, wrap-around eye protection, and gloves for this job. Go slowly, and rotate the light as you go. The disc may be melting glass more than cutting, but it will get the job done-just use extreme caution to avoid any personal injury.
4 When the groove is about...
4 When the groove is about 1/16 of an inch deep, get ready...
5 ... because all of a sudden,...
5 ... because all of a sudden, you will be holding two pieces.
6 Here it is: my very own...
6 Here it is: my very own T3 lens.
7 I used a grinder with a...
7 I used a grinder with a finer grit flap disc to smooth out the surface of the edge (of the housing).
8 If you are going to do...
8 If you are going to do this, you might as well get the best reflector. The German-made unit to the right is far superior in reflector quality, compared to the cheaper Asian counterpart on the left. The reflector is also deeper with a larger surface area. You do get what you pay for.
9 Although it is pretty obvious,...
9 Although it is pretty obvious, I marked the top position so the bulb will be clocked correctly.
10 To obtain the H4 reflectors,...
10 To obtain the H4 reflectors, I need to remove the glass. I filled the lamp with a shop towel to protect the reflector while I break the lens.
11 I broke the lens inside...
11 I broke the lens inside this heavy-duty contractor's garbage bag to prevent any flying glass shards. A firm but shallow tap will do it. Gloves and eye protection are a must!
12 Using needle-nose pliers,...
12 Using needle-nose pliers, I pried off the remaining glass; using a heat gun to soften up the adhesive works well here. I removed any remnant of glass and adhesive on the reflector edge with a sturdy knife.
13 Now is a good time to...
13 Now is a good time to do a test-fit.
14 If the lens doesn't get...
14 If the lens doesn't get seated well, you can bend out the edge a bit.
15 This will be the only...
15 This will be the only time you can access the lens from the inside, so make sure and clean it thoroughly now.
16 If you need to clean the...
16 If you need to clean the reflector before assembly, use air only, do your best not to touch the reflector-but if you happen to, use an alcohol wipe to carefully remove any fingerprints or smudges.
17 Using the comics for a...
17 Using the comics for a backdrop, I am laying down a bead of high-temp silicone adhesive about half the width of the contact surface. Don't be too liberal, as you don't want any adhesive to be squeezed in to the reflector when you install the lens.
18 Here it is: my very own...
18 Here it is: my very own high-performance T3 headlight.
19 Now I can install any...
19 Now I can install any caliber H4 halogen bulb that I want. You could even use an aftermarket HID bulb if you like.
20 When I install the lights,...
20 When I install the lights, I like to use contact grease on the connectors to eliminate future corrosion.
21 Note: The higher wattage...
21 Note: The higher wattage on the H4 bulbs will increase the load on the electrical system. Therefore, I added these relief relays (arrow) from Ron Francis for both the low and high beam circuit, thus eliminating any extra load on the older original wiring and switches.
22 The best of both worlds:...
22 The best of both worlds: vintage-looking T3 lights with European performance output.
23 As the sun sets on the...
23 As the sun sets on the Pacific coast, it's good to know that the powerful new headlights will assist in bringing me home safely.