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Ah, the crappy DOT lights thread lives on!
I too entertained thoughts of various conversions, adaptations, and
subterfuges to get some more light out of the crappy DOT lights on my 86 5KS.
I looked at a set of (very rusty) brackets from a 1979 5000, I looked at a
set of (very expensive) used lights for a 325 WMB, heck, I even went to the
local F*rd dealership carrying a tape measure, hoping I could find
something new and domestic (cheap) that I could adapt.
No luck. Each approach quickly became a MAJOR project.
Next step was to optimize the existing lights. A pair of Wagner Brite-Lite
9004 bulbs was the first, and unfortunately also the final step. I'm not
sure how much actual improvement there was, but I felt better, even if I
couldn't see much more in the dark. The problem is the crappy DOT design.
If you put a bigger bulb into it, the reflector melts. Even if it didn't,
the lens geometry is so poor that it wouldn't matter - you could put 10,000
watts per side and still be driving blind.
Finally, I bit the bullet and imported a set of genuine Eurolights - not
the UK version, but the continental version (they drive on the same side as
we do). They were not cheap, HOWEVER . . . they fit right, they work right,
and they look right. And Oh, Boy, do they light up the night for me, even
with 45/60 watt bulbs!!!
The next thing I did was import a batch of them - I am selling Eurolights
for the type 44 non-turbo cars (can be used on turbo cars if you change the
grille), including the orange corner lights, for $400 a set, complete. Add
your choice of H-4 headight bulbs, and relays (diagrams supplied), and SEE
NOW: For the next 30 days, until September 8th, I'll send $50 of the
purchase price of every set sold directly to Dan, our listmeister. Now you
have no excuse not to do this right!
P.S. Sold the old DOT lights on eBay - got $125 for the set!