H5 and sealed beam headlight conversion

[Cook&Dunning]

So there are plenty of threads and mods here starting with H4's. I decided to use my H5 headlights as a starting point. Once started, I realized this is obviously a way to modify your sugar scoops, too, using an H5 mounting bracket. I looked at using VW beetle reproduction parts as others here have, but I wasn't thrilled with the quality - so I ended up using genuine Hella and Porsche parts. All in I spent about $200 per light. If I had used the repros, it would have been closer to $100 a light. On my project I converted the H4 trim ring headlight aiming screws at 2 and 8 o'clock and so they are now used to secure the outer assembly along with the screw at 6 o'clock.


I disassembled the H5 - all you need is the bottom half of this alloy bracket - this has the 4 mounts that attach to the headlight bucket tabs



I bought a pair of sugar scoop / sealed beam assemblies off of a fellow Pelican. I pulled them apart - I stripped them down, painted the headlight carrier with black epoxy. Then I mated the Hella headlight carrier to the Bosch bracket. You can use either the H5 adjusting screws and springs or the Hella - both will work.



I decided to go with the Hella H4 flat face euro lights. Of course there are plenty of options here - I thought about yellow Hella lights, or LEDs, and I also like the look of Autopal crystal - I may switch it up in the future. Here is the completed headlight assembly.



Soldered on the H4 connector



Test fit the assembly. Here is a detail pic of my connectors that are positioned at 2'oclock and 8 o'clock for the additional screws that will secure the outer assembly along with the regular 6 o'clock screw. Next I aimed the headlights - I used Daniel Stern's instructions - very thorough.

[Cook&Dunning]

I bought a pair of H4 trim rings off of another Pelican. Underneath 6 layers of paint - nice original brass. I gave them a coat of epoxy primer and then some matt clear. This may change in the future once I paint the car.



I bought new Hella lenses from a guy in Germany. They came with Hella gaskets. I also ordered the inner trim rings and spring clips from Germany. These are Vewib brand, said to be made by Hella. I like this style because they do not have the hole at bottom for parking light. They came finished in a dull grey which works well on my silver car.



For a laugh I ordered a pair of Jeep trim rings - They are almost a dead nuts fit! I didn't follow through on this - not sure how I feel about Jeep parts on the car. These are abs plastic, also available in black.



The finished outer assembly. Just an fyi that you cannot use H5 trim rings - the glass lens does not fit.



The end result:

[The Welshman]

I have waiting for this thread for 18 months. Thank you!

[Cook&Dunning]

You are welcome! I hope you post up some pics of your lights.

[Hoss911sc]

I always wished that the Euro H4 had the more secure mounting of the H5. With the Euro H4 the fluting is on the outer lens. With this setup the fluting is recessed quite a bit, particularly at the bottom. How is the light pattern on the road? Does that recess limit the light pattern at all?

[famoroso]

Brilliant. Love the ingenuity! Well done sir!

Can you post part numbers and parts sources?

Can the sugar scoop "headlight carriers" be sourced new / separately?

I also prefer the inner trim rings sans hole for parking / city lights. My existing inner trim rings are powdercoated black, but have the holes.

So, if the H5 frame handles the aiming (a more robust and precise system than the 911 specific H1/H4 setup) and the 6 o'clock screw mounts the outer and inner trim ring assembly to the car so what do the two remaining original outer trim ring adjustment screws do?

[Cook&Dunning]

Originally Posted by Hoss911sc

I always wished that the Euro H4 had the more secure mounting of the H5. With the Euro H4 the fluting is on the outer lens. With this setup the fluting is recessed quite a bit, particularly at the bottom. How is the light pattern on the road? Does that recess limit the light pattern at all?

Hoss: I guess my honest answer whether the light pattern is affected is I am not sure. My reference light was the original H5 lens, badly pitted with a 25 year old bulb -so the new set up is much brighter. I am going to try and "restore" the old H5 glass for my next project, so if all goes well, I will put one back in and do a side by side comparo. You are right that the new set up recesses the H4 about 2" more than sugar scoop - but I did want to mention there is a slight flare outward on the inside trim - it actually slopes down from the H4 to the outer glass, and also wider at sides - if that makes sense. I can measure up, but I think this makes the adjustment.

I built these thinking they would have the SWB / 356 look - so I think an H1 is probably the more proper part - but I have seen Hella H4's on SWB and 356's - so maybe someone on Pelican has tried this before?

[Cook&Dunning]

Originally Posted by famoroso

Brilliant. Love the ingenuity! Well done sir!

Can you post part numbers and parts sources?

Can the sugar scoop "headlight carriers" be sourced new / separately?

I also prefer the inner trim rings sans hole for parking / city lights. My existing inner trim rings are powdercoated black, but have the holes.

So, if the H5 frame handles the aiming (a more robust and precise system than the 911 specific H1/H4 setup) and the 6 o'clock screw mounts the outer and inner trim ring assembly to the car so what do the two remaining original outer trim ring adjustment screws do?

Hi Famorosa - I will pm parts suppliers. You can buy headlight carrier aftermarket, they are the same as VW beetle 67 and earlier - but just an fyi - sugar scoop parts are easily available here on classifieds.


You are right that the headlight aiming now happens inside on the H5 mounting bracket. I am using the H4 trim ring holes at 2 o'clock, 6 o'clock and 8 o'clock to secure the outer assembly. I am only using one trim ring per side - not the inner / outer set up. Just one brass ring shown in pics

[Cook&Dunning]

a couple of follow up pics for those who have asked.

This is the new position of sealed beam


this is the part number of headlight bucket

[PTrickey]

Forgive me if I missed it but where did you source this part from?

[Cook&Dunning]

Everything for that little bracket is from Lowes. That is a strip of aluminum that I just cut to size and bent to shape. There is a screw on the backside holding the threaded tube part in place with a little jb weld. Not very pretty, but it worked.

[PTrickey]

Perfect! That is what I needed to know.

Thanks!

-Phillip

[DRACO A5OG]

How is the light cast from the Mod? Pics?

[Cook&Dunning]

Draco - I do not have any pics - I did this mod last winter. I assume the light was the same as any other H4 E sealed light. The Hella H4 had a yellow tinge light. I decided to change it up again and went with LED bulbs in the old H5 assemblies.

[ARad]

Originally Posted by PTrickey

Forgive me if I missed it but where did you source this part from?

Exactly what is this bracket for? For the headlight trim ring screw? What is the bracket CALLED if I go to Lowe's and inquire specifically as to pinpoint where to find this particular bracket in huge warehouse full of inventories at Lowe's ? Please advise.

[Cook&Dunning]

Yes - the brackets are to hold trim rings in place. 2 per headlight The threaded tube piece (I don't recall the actual part name - was in the fastener aisle. The rest of the bracket I made from a strip of aluminum, the threaded tube piece, and there is also a screw with JB weld from the back side of bracket, securing the threaded tube.

[DeRRis]

Originally Posted by Cook&Dunning

I bought new Hella lenses from a guy in Germany. They came with Hella gaskets. I also ordered the inner trim rings and spring clips from Germany. These are Vewib brand, said to be made by Hella. I like this style because they do not have the hole at bottom for parking light. They came finished in a dull grey which works well on my silver car.

Did you have a hard time fitting the Hella gaskets. Mine came in today but the are a real stretch!

[HaroldMHedge]

ARad,

Try searching for "Rod Coupling" at Lowe's or other hardware store for the internally threaded piece.

[dlagerstrom]

I love this idea. Sure seems to be a more solid mounting. I have been collecting the parts so I can do this as well.

How did you modify the bucket to fit and still hide all of the mounting parts? It seems if you just cut it shorter it will fit but you would be able to see the mount.

Thanks

[AVVG Studio]

More easiest way:

Check this video about the headlight Conversion methods, adapters, and It's advantages.

Click on the Image: