Astra J - Headlight Cap for retrofitting Osram Night Breaker H7 LEDs

thingiverse

This headlight cap is designed for enabling the retrofitting of the official Osram Night Breaker H7 LEDs by creating enough room for the LED cooler. It fits the model Vauxhall/Opel Astra J and might also work on other models using the same kind of cap. The parts use the rubber seals from the original caps. The through hole is for connecting the LEDSC01 adapter units, an additional file without the hole is provided in case these units should not be necessary. Due to the heat generated by the LED, the proximity to the engine and the warming of the car when it is parked in direct sunlight, I recommend using a heat resistant material, ideally ABS (PET-G might also suffice). PLA shouldn't be used for this under any circumstances! I managed to successfully print the parts first try using temperatures of 240°C/110°C for ABS(+ an enclosure made out of aluminium foil for the 3D printer), 50% infill, 50 mm/s, no raft and no brim on my AnyCubic i3 in about 6h each, using 140 g of material in total. The caps fit tightly and securely, but there aren't any insights on how they fare in the long run yet. I would be happy to see your successful prints and to hear some feedback. Good luck!