Date: Fri, 8 Jan 1999 22:22:45 +0100
Reply-To: Helmut Zeidler <Helmut_Zeidler@NOTESMAIL.NOKIA.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Helmut Zeidler <Helmut_Zeidler@NOTESMAIL.NOKIA.COM>
Subject: Bosch DE headlights replaces DOT rectangulars, Vangon too
Content-type: text/plain; charset=us-ascii
Hello All,
My '80 Vanagon is still equipped with some dark 45/55 Watts Bilux
headlights. They should be upgraded, choices are standard round H4,
standard rectangular H4, Projektzwo grille with H4 or DE headlights. The
South Africa quad round could also be a choice. I would love to get some
DE headlight system like those sold by Projektzwo, but I will not spend the
480.- USD for that system.
A few days ago I got a catalog of auto and truck parts, and I tested if it
is usable to find common parts of different vehicle makes. I remembered
my headlight problem and tried my luck. Start was the headlight system of
my disassembled '82 Audi 200. Its the four quad headlight system with H4
dual and H1 high beams which meets both the dimensions of DOT 6.5x4.2 inch
standard headlights. I checked, what kind of cars are using this
headlights. I got a list of more than twenty different cars with German
and Japan origin and sold on the German market. On the trucks list I tried
same. On the high beams I found some coaches using this Audi H1. But on
low beams, this coaches were delivered with Bosch DE headlights on same
dimensions of DOT 6.5x4.2 inch standards. This can't be an accident.
After some thoughts back and forth I ordered the left Bosch DE headlight
to test it. It will go into the Audi frame and with some brackets it will
replace the round Vanagon headlights. That's the plan. If the headlight
will not fit I can accept the loss of 81.- USD I spent for the headlight.
I got the Bosch DE Headlight for testing today. The headlight frame was
disassembled and I replaced the outer H4 headlight. The Bosch headlight
fits perfectly into the DOT frame, I'm sure, it is designed for this.
That's for now.
But there are two minus:
The outer lens of the Boschs is flat, it is on same level as the outer
securing DOT brackets. The AUDI lenses (lights are made by Hella) do have
their surface 0.7 inches in front of the brackets. This is an optical
minus, the headlight mask of AUDI 200 ends at same level as the securing
brackets. It will be possible to get a view of the inner mountings looking
beside the lenses. Additionally the DE looks deeper inside the grille as
the H1.
The other minus is, that the DE builds deeper into the grille as the H4.
In total the DE is 7.6 inches deep, the H4 only 4.5 inches (but w/o bulb
sockets). I will check if the DE will fit into the Vanagon on left side,
as this side is more difficult because of cabelings. The Projektzwo fits,
and I guess, the Bosch will fit, too.
Of cause, the grille have to be modified. The headlight mask of the Audi
measures about 15.6x6.0 inches and I wonder, if the Vanagon rectangular
grille will fit.
What's about the costs of this project? Two Bosch DE headlights, 81.- USD
each, two H1 bulbs, 3.- USD each, and some other parts adds up to about
200.- USD. Audi 200 DOT headlight frames, H1 high beams and headlight mask
should be added, too, but this parts are boring around in my warehouse.
The total price is significantly below the price of Projektzwo, grille and
brackets have to be made by my own.
I will keep you informed about the ongoing project.
For those owning vehicles with DOT 6.5x4.2 inch rectangular headlights:
You can easily upgrade to the Bosch DE lights if the free space behind the
mounting brackets exceeds 6.5 inches. To get that measurement, just remove
the low beams by releasing the four mounting screws of the securing
bracket. On the four edges of the mounting brackets there are rectangular
holes. From the surface of this hole, measure into the car on every of the
four edges. If there are more than 6.5 inches, order your set of DE
headlights. No modifications other than replacing the bulb sockets are
needed.
Regards
Helmut
'80 Vanagaudi
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