Replacement Headlights - Will 7" round fit - Toyota FJ Cruiser Forum
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post #1 of 32 (permalink) Old 07-07-2010, 08:00 PM Thread Starter
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Replacement Headlights - Will 7" round fit

I know there are a couple of other posts about the modification of the original headlights to house projector style beams, but I would like to know if anyone has mounted 7" delta lead crystal headlights into the factory mounts, or if they know this is not possible. I used these on my old jeep and loved the light out of them with xenon bulbs with no projector and very little spill light. I would love to use these again, but I can't find anything on anyone using these on an FJ.
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post #2 of 32 (permalink) Old 07-07-2010, 08:16 PM
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Re: Replacement Headlights - Will 7" round fit

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I know there are a couple of other posts about the modification of the original headlights to house projector style beams, but I would like to know if anyone has mounted 7" delta lead crystal headlights into the factory mounts, or if they know this is not possible. I used these on my old jeep and loved the light out of them with xenon bulbs with no projector and very little spill light. I would love to use these again, but I can't find anything on anyone using these on an FJ.
While it might be possible with a lot of modification, it's not likely to work well. The projector inserts are designed to be installed inside the FJ's lens assembly. But 7" round lights have no support frame, and without a mounting cup you're not likely to get them aimed very accurately. The FJ uses a molded, free-form reflector / lens combo with integrated mounting structure for it's headlights. I've tried virtually every light out there, and I'd wager the FJ's headlight lens will put out more light and a better pattern than the Delta 7" round replacement headlights, even if could make them fit. So, I'd suggest focusing (pun intended) on a better bulb rather than replacing the housing...

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post #3 of 32 (permalink) Old 07-07-2010, 08:39 PM
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Re: Replacement Headlights - Will 7" round fit

You might want to take a look at Philips X-treme bulbs. Just a suggestion

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post #4 of 32 (permalink) Old 02-19-2012, 11:00 PM Thread Starter
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Re: Replacement Headlights - Will 7" round fit

Ok... So I am reviving a REALLY old thread of mine to update it a bit. I always liked the pattern and clarity of the Delta Euro lights I had with my old (um sorry guys....) Jeep. My original desire was to replace the stock FJ lights with these, but I was discouraged from doing it since it had never been done, and because of course, everything Toyota makes is perfect. Hogwash! I settled for putting an HID conversion bulb into my stock housings and got a ton of light, but sacrificed longevity since the HID bleaches the cheap plastic innards of the FJ's housing and turns the silver reflectors white and cloudy resulting in an absolutely worthless set-up in little less then 2 years.

This brings me back to here. I got fed up with settling, and did not want to settle again or go through the issues of placing some HID projector kit into the housing that may, or may not hold up when it is subjected to the abuse of going off-road on a regular basis.

I purchased the Delta Euro lights in the 7" round set-up and set about deconstructing the stock housings to see if I could make it work. Where I sit now is I need to make a simple ring to mount the lights to that will mount to the stock light bucket from Toyota. I need to find a custom metal fab shop in Dallas that can help me with this as it is a bit past my basic abilities.

Anyone have the name of a good fab shop in Dallas? The project is literally 2 rings and 6 bolts away from becoming a reality, and will be WELL worth it. I took both lights and set them up on my truck on a side-by-side comparison, and the Delta's give a much more controlled pattern with better low-ground spread for low-beam usage, and a MUCH longer throw for the high-beams with a much better clarity and no chance for fading or fogging since they are glass and chromed metal instead of plastic.

Any help you guys can give me would be much appreciated.
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post #5 of 32 (permalink) Old 02-19-2012, 11:49 PM
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Re: Replacement Headlights - Will 7" round fit

How about going Ol' Skool and using some headlight bucket parts off an older vehicle? Scroll down this page a bit and you'll see what I mean....

Specter Off-Road Land Cruiser Parts - Page 112 Land Cruiser Body Parts

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post #6 of 32 (permalink) Old 02-20-2012, 07:28 AM Thread Starter
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Quote:
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How about going Ol' Skool and using some headlight bucket parts off an older vehicle? Scroll down this page a bit and you'll see what I mean....

Specter Off-Road Land Cruiser Parts - Page 112 Land Cruiser Body Parts
Wow. This is why i love this forum. Great idea, however,what i need is even simpler than that. I literally need just a flat 8" ring 1" wide made out of 1/4" aluminum or 10ga steel.

The buckets on the '40 look like they might hold every thing, however, it dosnt solve the problm of mounting to the stock fj housings.

I can hack out some rings with my grinder and dremel, but keeping them round and clean looking is tough with basic tools.

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post #7 of 32 (permalink) Old 02-20-2012, 08:02 AM
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Re: Replacement Headlights - Will 7" round fit

Does it need to be metal? Can it be polymer? If so you could make it out of kingboard or acrylic. All you need is a drill press and a circle cutter. You could probably purchase both for less than it would cost for the fab shop to it
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post #8 of 32 (permalink) Old 02-20-2012, 10:48 AM Thread Starter
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I haven't worked with either of those materials. How rigid and shock resistant are they? I only ask because the delta lights are a bit heavier then the stock ones, and I would hate for them to crack or break under stress from a big bump.


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post #9 of 32 (permalink) Old 02-20-2012, 11:42 AM
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Re: Replacement Headlights - Will 7" round fit

Post pix, napkins drawings or something of where you're at w/ this and we'll see what else we can come up with.

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post #10 of 32 (permalink) Old 02-22-2012, 07:42 AM Thread Starter
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Re: Replacement Headlights - Will 7" round fit

Well, the project has been sitting for a few days now due to a heavy work load this week, but here are a couple pictures of the idea/progress. I am going to try to make the rings out of acrylic cutting-board material. It seems to be fairly heat resistant, rigid, and it is a heck of a lot easier to cut and shape then steel or aluminum.

Basic light dissasembled. You can see I tried to mount the new light inside the old bucket, but that failed due to the plastic being too britle.


The housing with no bucket installed.


the main components all together. (ring is a paper mock up)


Back of the delta light. It has 4 mounting tabs built in, but not eavenly spaced around the light.


Ring in the Housing.... Going to be tight, but that is ok... the tabs on the lights are 1/8" too far out, so I will have to drill my mounting holes slightly inside and "Pull" the tabs in-line.



basic idea of how it will look mounted and finished.



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