H7 LED Headlamp Bulb Holder / Adaptor for Novsight

thingiverse

I got tired of a friend's Novsight XHP50 LED headlight upgrades temporarily blinding me, so I decided to take matters into my own hands and create these adapters. The problem with these headlight upgrades is that they're incredibly bright, which is exactly what you'd expect from them. However, the LED chips aren't precisely where they should be within the headlight reflector. This results in reduced light output on the road ahead and increased glare for other drivers in the path of the headlights. I measured the original lamp adapters against the H7 bulb specifications and found that they were significantly off. Add to this the poor fit between the lamp unit and the adapter supplied, and you quickly end up with a very poorly set-up headlight "upgrade." These adapters are specifically designed 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 the filament to be 25 mm +/- 0.2 mm from the mounting plate's upper face, and the original design placed the LED chip at a distance of around 27-28 mm while also allowing the bulbs to move slightly over bumps. I've shared these adapters because they were a huge success on my friend's car, even inspiring me to get some for my own vehicle. You may notice that these adapters don't have mounting slots - this is by design, as they're intended to fit snugly in place (you'll likely need to sand them unless you mess around with horizontal offsets in your slicer) to securely hold the bulbs while allowing 360-degree adjustability for optimal light output, beam pattern, and reduced glare.