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headlamp conversion 200 1989

posted by  JimSig on  Sat Mar 17 16:21 CST 2007
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last visit: Fri Mar 28 17:24 CST 2014
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I have a pair of hella front headlamp clusters (dual round glass lamps) that came out of late 80's mercedes - I think these same clusters were used on mid to late 80's bmw 300 series too. I thought about trying to fit these into my 89 240 to try to improve the lighting. I know it would probably require rewiring a complete new circuit with proper relays but I'm more curious at this point if anyone else has attempted this same conversion and if they were able to successfully fit them. Rough measurements look like the fit would be tight at best - just wondering if anyone else has already tried and could share their experience.

Jim








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    headlamp conversion 200 1989

    posted by  Maxspeed on  Sat Mar 17 16:41 CST 2007
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    last visit: Mon Jan 20 21:55 CST 2014
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    There are several posts in the archives on the subject. Not sure about using the Mercedes ones. I have seen a few after alteration. Some are quite good and there are a few dogs.. Yes, going with a pair of relays is the only way to do it due to the small gauge wire to the headlights. I installed a set of Ecodes and added a pair of 80/100 watt bulbs I got online. I can see Mars from my driveway.. There are several aftermarket companies that offer a replacement. D&J Auto(I think) and others that have been discussed in the archives. I installed a set of the DJ's on a friends 90 244. I installed a pair of motorcycle bulbs rated at 100/130 watts. He loves his new lights as he does a great deal of long distance driving at night..These things are bright.. Not really legal but in 4 years he has not been stopped once. And the on coming cars are not really effected due to really good light aiming. A little brighter but not really blinding.
    --
    Max..1989 244 DL 5 Spd., V15 Phase II Cam Bilstein HD, Turbo Swaybars, Poly Bushings all round, Turbo Wheels, Black leather interior, Electric mirrors, LED dash and gauge lights and now NEW ECODES with the turn signals, 1992 black 244 next project








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      headlamp conversion 200 1989

      posted by  JimSig on  Sun Mar 18 01:39 CST 2007
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      last visit: Fri Mar 28 17:24 CST 2014
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      Thanks Max!

      I found several posts in the archives about conversions using the clusters from flathood volvos, but nothing about using these hella clusters that late 80's bmw and mercedes wear. I'm thinking that after I find a way to firmly mount the clusters I will try to use the trim/filler panels from the bmw which should be able to be cut off on the inside edge for a good fit next to the grill (they are horizontal black fins). I'd probably use a black turbo 740 grill to get a better look too - of course it all sounds easy on paper! That's why I was looking from any input from anyone who might have already attempted this conversion.

      Jim








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        headlamp conversion 200 1989

        uid 25912's pic
        posted by  Sven's Maintainer on  Sun Mar 18 05:37 CST 2007
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        last visit: Sun Sep 16 20:44 CST 2012
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        Good to see your post! I'm always glad to see another person ready to tackle a headlight conversion on an '86+ 240. See my car's pic below...

        My e-code conversion uses 6" x 8" headlamp buckets from an early '90's Isuzu pickup. I considered Mercedes but the 6x8 ones I pulled would have been very difficult to fabricate into the 240. The assembly was a plastic casting with a "stepped" rear surface - that is, not a flat plane. The headlight buckets I got instead have four mounting "feet" that made that part of the project a bit easier.

        The 240 radiator support bracket is basically a flat plane going across so plan around that fact. If you're committed to the M-B assembly then plan on building up the rear as needed to meet the 240's flat plane.

        Also re. grilles - you may need a narrower grill than the '89 grill. The '86+ 240 grill only allows for the 13" width of the headlight lens. The earlier 240 grill is narrower and also taller. Of course narrower will fit however the outer ends of grill will not line up with the hood's raised center portion. What may be a larger concern is that I believe the total height of grill is greater than the space available in the '86+ 240. You can change that metal strip but I wasn't willing to get into sheet metal work that would require finishing and paint matching and probably spot welding.

        If the grill story is as I described above, and you need a narrower grill, check some of the newer Volvos in junkyards. Attachment methods will be different but you'll be doing your share of fabrication anyway. If an 850 or 940/960 grill meets your needs then go for it.

        I used www.rallylights.com as my source for e-code housings and H4 bulbs. Headlight relays from junkyard 240s. Those relays are stamped as handling 15A x two output terminals. You should add diodes outside the relays to cancel out back emf when you shut off the headlights - it shut down my radio several times weekly until I added the diodes. Read about it at rallylights.com under "tech information" or something like that - there's a tech know-how section on the site.
        --
        Sven: '89 245 NA, 951 ECU, open-front airbox, E-fan, 205/65-15's, IPD sways, E-Codes, amber front corner reflectors, quad horns. Wifemobile '89 245 NA stock. 90 244 NA spare, runs.









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          headlamp conversion 200 1989

          posted by  JimSig on  Sun Mar 18 15:29 CST 2007
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          last visit: Fri Mar 28 17:24 CST 2014
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          Well, I took the right front headlamp assembly out today to see if the Hella dual round assembly could be made to fit. Actually found there would be plenty of room but would need to fabricate three brackets to hold the assembly in place (not too difficult - and also a bracket to hold the corner turn signal in place since the attachment points to the headlamp mount would be removed - also not too difficult. I played around with just where to place them left to right for the best look and liked the general look - particularly if enough space is left between the corner light and the headlamps - would mean fabricating a narrower grill, but again not impossible to do. I did find though that the offset between the fronts of the two round lenses on the clusters I have is too severe for the front end of a 240 - either one lamp would protrude too far out or the other would be buried too deep - so I'm going to keep looking for a more suitable headlamp mount to use.

          Jim








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            headlamp conversion 200 1989

            uid 25912's pic
            posted by  Sven's Maintainer on  Mon Mar 19 02:19 CST 2007
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            last visit: Sun Sep 16 20:44 CST 2012
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            Yes - I forgot about the offset but I saw that difference also. The 240 front has an angle but no as severe as either the Mercedes or BMW, as I recall. Junkyards are your friend here, as long as you have the time to walk around and keep looking at things and trying different options.

            A battery-powered Dremel + reinforced cutoff wheels might also be your friend if you find lots of rusted headlight mount bolts.
            --
            Sven: '89 245 NA, 951 ECU, open-front airbox, E-fan, 205/65-15's, IPD sways, E-Codes, amber front corner reflectors, quad horns. Wifemobile '89 245 NA stock. 90 244 NA spare, runs.







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