H7 LED Headlamp Bulb Holder / Adaptor for Novsight

thingiverse

I got tired of a friend of mine blinding me with his Novsight XHP50 LED headlight upgrades, so set about making these adapters. The trouble with the headlight upgrades is that they're really bright (as you would hope!) but the LED chips aren't located exactly where they should be in the headlight reflector. This means less light output on the road in front, and more glare to any other road users in the path of the headlights. I measured the original lamp adapters against the H7 bulb specifications and of course they were quite off. Add to that the poor fit between the lamp unit and the adaptor they supply and you quickly have a very poorly setup headlight "upgrade." These are made specifically for the green version of the Novsight LED headlights shown in the photo, which have a distance of 35mm from the top of the heatsink to the bottom of the CREE XHP50 chips. The H7 specifications call for the bottom of filament to be 25 mm +/- 0.2 mm from the mounting plate upper face and the original design put the LED chip at a distance of around 27-28 mm whilst also allowing the bulbs to jump about over bumps etc. I have published these because they were a raving success on my friend's car, even made me want to get some for my own car ;) You might notice these do not have the mounting slots in - that's because they're designed as a tight fit (you will likely need to sand unless you mess about with horizontal offsets in you slicer) in order that the bulbs are held super securely whilst being fully 360 degree adjustable to get the most effective light output, beam pattern, and lowest glare.