in for installed comparison pics!

All i can think about after seeing these pictures is Iron Man 2. You sir, have created a new element.

@Acree think you could post up a whiteboard diagram of what the modified boomerang circuit looks like?

Yes sir, I will take care of that tomorrow.

:thumbup: Thanks a lot!

While this looks amazing, the end of this line is my concern:

Even with the correct thermal management, what are we looking at for reduced life of these LEDs? Some, none? Any input you have would be appreciated prior to me setting out to make this change.

I did all of my testing with an infrared thermometer directly onto the heatsink. (Full disclosure, the manufacturer recommends the use of a thermal probe near the thermal mounting pad of the LED, but I do not believe that is necessary in this application.)

I never saw temperatures over 60*C on the heatsink with them being on for an hour straight. Now, two caveats with this: 1) This is with an ambient temperature of 72*F or 22*C. 2) This leaves a temperature increase of 30*C at a minimum before I would even begin to worry about diminished LED life. Even in the direct sunlight on a 110*F Texas day, I don't believe the LEDs will ever get hot enough to worry about overheating or shortended life spans.

The main reason I made that statement was so people would be very conservative when trimming the heatsink. If you go ahead and chop off half of the fins, then the thermal resistance would be close to double of what it used to be. In other words, it would dissipate heat half as well. That's bad.

whats your thoughts on using slightly smaller heatsink fins? I have a bunch of 25x25x13 laying around.

As long as the thermal resistance is damn close to 15.6 or lower, no problem.

Do you have any pictures with the boomerang assembly on the headlight enclosure? I wanted to see the clearance between the heatsink and the headlight assembly. Assuming there is enough space, wouldnt a lower but wider profile heatsink work better? Lets say, 30x30x10mm?

I do not have any photos of that. I'm sure there are a number of different configurations that would fit. I just bought 4 of the same heatsinks that I knew had a small enough footprint for both locations.

Thanks. Seems like you've looked into this a lot. Another question if you dont mind, so with the DRL's, what are they hooked onto? You said there is no circuitry in the DRL module itself, so I'm assuming its just an led strip? I'm thinking of doing this mod but i'm gonna incorporate the dimmer instead of just cutting it out.

Here ya go.

http://www.hidplanet.com/forums/show...GHTS-INTERNALS

:cry:

Why do I have to be so electrically incompetent!?! This sounds like something I'd like to do, but something I'd hate to have to do myself.