For the longest time, I have watched the evolution of the Led 7" round headlight technology and recently decided to upgrade to a set that fairly well mimic the look of the stock glass sealed beams at a reasonable price. I did not want the projector Hid look, too high tech looking, plastic, fan cooling, or a blue light hue. The set I found was from Vintage Car Leds who aim their products at the customer who wants the oem glass look with the advantages of Led bulbs.
I chose the 3500 series of their lamps which are moderately priced, and appeared that with the bulb (4000 LM) / heat sink installed (no silly fan) would fit in the confines of the S30 housing.
Of course as many are aware, Nissan and many other Japanese auto companies use negative switching of the ground side of the headlight system, the Led's expect the positive side to switch. That being said & with Dave Irwin no longer an option to supply the 240 kit (easy to adapt to the 280 style round connectors) I decided to build my own high quality negative switched harness. I did not want to hack the oem wiring, so I replaced the lighting harness all the way to the headlight buckets.
I used real 12 gauge copper wire for the main power source and 14 gauge on the heavy lifting side of the relays feeding the headlights. On the low current trigger side from the combo switch to the relays is 16 gauge.
My main intent was to make everything reversible without any modifications should the day ever come to put the system back to factory spec.
The headlight assembly fits in the stock housing and its inside bracket but its a close fit, I tried using my bore scope camera thru the bucket grommet hole but could not get a worthwhile picture as it is difficult to maneuver in there. Looked to be about 1/16" clearance. The one gripe I have is that the pigtail from the bulb exits at the back of the heat sink, wish is was the side to provide more clearance. I also upgraded the headlight plug connector to a more heat resistant porcelain type. This plus into the pigtail from the Led bulb.
The upshot of all this is ........ a dramatic change in usable light compared to the sealed beams without blinding oncoming traffic. Also,the very low current now thru the combination switch, I was saving a nos combo switch that I just installed which has never seen full load current - it should last a very long time.
Impressed so far, will try to get some action pictures driving after dark, but so far - highly recommended.
In other news .... I am playing around with the fog / driving lights as a inexpensive solution to fill the gap below the 240 bumper. Its still in progress, a fun project, will notch the fabricated bar I made to clear the lower grill mount and get them about an inch or more lower. Again, all factory mount holes were utilized, including relocating the horns.