Headlight Dust Caps Too Shallow For LED Upgrades? Here's How To FIX It!

[@InJasonsGarage]

*I mention Colorado trucks in this video, but these solutions can work for other vehicles, too!* Are your headlight dust caps too shallow for LED upgrades? Here's some solutions! Quick jump to each section 0:00 - Introduction 0:59 - Some lights fit, some don't 1:20 - What about heat issues? Not an issue! 2:20 - Option 1 - Go without dust caps - DO NOT DO THIS! 3:51 - Option 2 - The "Hack and Stack" method 4:54 - Option 3 - Use an A286 cap extension (more info at www.coloradofans.com/threads/morimoto-2stroke-3-0-led-h11-bulbs.425718/) 6:15 - Option 4 - (my favorite) 3D printed dust cap (more info at kzbin.info/www/bejne/rJaqd3ikm5ihebs) 9:07 - Installing the 3D printed dust cap 9:28 - Conclusion

[@WarPonyAuto]

Just sayin…. And many will oppose what I say, but I’ve been installing LEDS since they started to really catch on and most headlight assemblies are compartmentalized. With projector assemblies the face are sealed separate from the backside where the bulbs insert. With traditional halogens you didn’t want the base to get wet hence the caps and closing them up but with LEDS with fans they are water proof assemblies/housings and the there is a rubber seal around the shaft of the led that seals between the led bulb housing and the lens bowl so the rear caps are not needed. I’ve seen people do stuff like this and end up with burnt out LEDS as that heat has no where to escape. That fan just pushed around the got air rather than getting fresh air to cool the LED housing. BUT… to each their own. My 08 Titan has been running for years with no caps as the front on the housing is sealed separately from the back side. And I’ve had zero issues. My GMC Envoy, Ram and every other vehicle I’ve owned the caps are not installed and I have zero issues. Granted sone older vehicles may be different.

[@lumarkid]

i always wondered this.. thanks for that info.. gonna order leds right now.. been having hids for the past 7 years and my dustcap had a cutout hole to pass the ballast wires through.. only reason i haven't upgraded to led is because i can't find any dustcaps to fit my headlights... but now i'll run them without them

[@californiacupcake8580]

Thank you!!

[@doriangreen3231]

I think Amazon has some dust covers that are made to fit LED lights. I bought some for my F150 a few years ago and they worked great.

[@HorsePowerObsessed]

Great video, Jason. I'm glad you like them!

[@InJasonsGarage]

Thank YOU, buddy! 👍

[@keithbartlett7679]

Hey horsepower obsessed I have a 2013 terrain the dust caps nearly flush with the rear of the housing, desperately need larger caps. I'm curious as the canyon and Terrain are in the same family. If some would be available soon.

[@diyi75]

I've installed led headlights in many vehicles. The fan/heatsink has to have open air of some sort. If it's inside the dust cap, the driver will throttle the unit, dim it eventually, and fail. I've experimented on one of mine, after a few weeks, the side with the dust cap malfunctioned. Dust caps have to be vented in some way if led light are used. The bulbs gasket should keep dust, debri & moisture out of the lense area. If it doesn't, housing is inferior or the bulb gasket is inferior.

[@514aam]

Carrover makes special dust caps for LEDs. Leaves the heatsink outside the enclosure. Definetly will help reliability and light retention when operating.

[@contagiousingenuityagency5273]

Hi Jason, do you happen to know which filament the guy made these dust caps of? If it's PLA, that tends not to fare well with hot temperatures. It simply may melt in the toasty engine compartment paired with the heat of the bulbs themselves.

[@HorsePowerObsessed]

It is not PLA, it is PETG. 👍👍

[@contagiousingenuityagency5273]

@@HorsePowerObsessed Got it, thanks!

[@emmanuelebenesar]

Am using osram H4 LED which has a fan behind the led and a ballast my dust caps can easily fit all these items... But my doubt is, do i have to put holes on the dust cap for air ventilation?

[@InJasonsGarage]

Definitely not. They need to be sealed to keep debris and moisture out of the headlight housing. I measured a halogen H11 at around 300 degrees f. Most quality LED headlights with decent heat management will run around 125-140 degrees f.

[@ConceptXX]

Which part number are your Osram H4s?

[@richardmalone6658]

What I could find that fit just right was Bojangles sides containers. I just had to trim the lip off the containers. It wasn't that the extenders weren't deep enough, the fan was hitting the side of the original dust cap. Colorado's has a large offset off bulb compared to the dust cap opening. Hope this helps someone.

[@InJasonsGarage]

You may want to check them once in a while...the heat generated by the LED bulb may melt them. Then again...they are designed to contain hot (and awesome) food.

[@richardmalone6658]

Will do

[@AndyNav1]

The heat sinks generate a lot of heat. Do these dust caps allow heat to escape?

[@InJasonsGarage]

No, and neither do the factory dust caps. These are just extended versions of the factory dust cap style. Factory halogens run MUCH hotter than any LED I have tested. Check this out: kzbin.infoH8VP762ApdA

[@FearDNone]

is it safe to put everything inside the cap? I mean including the external LED driver?

[@InJasonsGarage]

That depends on the material of the dust cap and of course, if it fits. In the case with my truck, I was able to tuck the driver into the headlight housing.

[@FearDNone]

have an old Chevy venture and already installed LED bulbs without driver and it fits and for quite some time, I never saw any issues with the cap (no signs of heat residue or melting). I am sure an external driver will fit but just wanted to make sure it will be ok based on the current setup. @@InJasonsGarage

[@InJasonsGarage]

@@FearDNone It should as long as it fits but it also depends on the LED headlight upgrade you install and how hot it gets. I would check it every time you lift the hood, just to be safe.

[@FearDNone]

@@InJasonsGarage great tip! I also saw some universal rubber dust caps online, will also look into it in case. Thanks man!

[@megatron6771]

I just installed leds in my 2013 ram sport with projecter head lights do i need to drill some holes to move air around

[@InJasonsGarage]

No, you should not do that. Halogen lights get much hotter than LED and they don't need that. Drilling holes will introduce junk into your headlight capsule.

[@richardmalone6658]

Ordered those a286 cap extentions, cut my dust caps and it would not fit. The 2019 Colorado has to great an offset in the low beam for a GTR ultra 2. I had to cut a bigger hole and use plastic containers to make it fit.

[@InJasonsGarage]

What kind of containers did you use?

[@renaissanceengineering-lee4210]

I don't think you understand the reason for the heatsink. Regardless of whether the LED is half the temp of halogen bulbs, improper thermal management will cause the LED lifespan to be significantly decreased, and could degrade some of the lower temp materials used to assemble the light (epoxy, plastic, etc.). It's better to risk getting dust around that area than to have $80-120 LED bulbs constantly burning out after getting dimmer and dimmer. You can also just use a rubber skirt around the bulb that leaves the heatsink exposed as well. Source: I worked as an LED Heatsink Engineer

[@InJasonsGarage]

Removing the dust caps will allow for dust to get inside the headlight housing, not just around the area where the heatsink is but inside the reflector/projector/lens area itself, blocking the light, reducing output and looking terrible. Dust caps are there for a reason. In a world where auto manufacturers will save pennies per vehicle by using cheaper materials, if the dust caps weren't important they wouldn't design them to be included.

[@renaissanceengineering-lee4210]

@@InJasonsGarage I'm well aware of automotive engineering principals. If dust gets on a 300 degree halogen bulb, then it causes impurities on the glass and can burn the bulb out very quickly and that would be an unacceptable failure mode. Water getting on H1 plugs can also short them out causing another unacceptable failure mode for the manufacturer. If you're using LED then getting dust in a housing won't be detrimental to bulb life due to their design, and if you waterproof your connectors (with Delphi plugs) then the dust covers *will* affect your bulbs lifespan and can cause thermal throttling and decreased brightness depending on the LED driver design. A terrific compromise would be looking into LED silicone boots/skirts that allow the heatsink to be exposed to the air and prevent dust ingress. My main point was that just because LED lights don't get as hot as halogen bulbs, doesn't mean anything since the temps affect the LED lifespan and brightness. If you're going to run overheated LEDs, you'd be better off with halogens for safety and visibility.

[@himanshuyadav-qj7xp]

Will led working if u put on polo geniune dust cover back

[@InJasonsGarage]

Can you ask that a different way?

[@ConceptXX]

Wish someone made something for my vehicle,and any modification I have seen or done myself I just wasn't 100% happy with. I've run no caps for 7 years now on one of my cars lol. 2 years on another, both No issues that I've found, however would not recommend.

[@paedahe4975]

If your considering this, what ever you do, don’t use purple lights. They look hideous.

[@InJasonsGarage]

Not only that, they are unsafe to use as they are not effective for night vision like white colors.

[@ConceptXX]

Purple?? Who and where?? Can't say I've ever seen purple LEDs, at least not in headlamps

[@paedahe4975]

@@ConceptXX It’s not very common, as whoever has done it gets pulled over, ticketed or warned to replace or else, but they sell them on EBay, and it really just depends on the car.

[@ConceptXX]

@@paedahe4975 so stupid. Back in the day when we just got our licenses and first cars we'd change our park lights and license plate lights whenever we'd meet up, as it would usually involve burnouts and some drifts. It just kind of made things more colourful and fun, just the smallest amount. Both used the same wedge globes and only took a couple minutes. Good harmless fun for us when just about every modification was illegal. Pretty lame but even then if we saw someone using purple headlights they'd probably get them smashed in just for being an absolute idiot

[@ORLANDOBUSA]

Hi What about Dodge ram hemi 2017 , i cant find it for my large leds, need them deep, dodge ram headlight extension seal cap waterproof dust cover

[@InJasonsGarage]

Fair question. Even though I made this video for my personal vehicle, I intended for it to be a guide for ALL vehicles that have the same issue. My suggestion, if it helps, is to follow the same advice no matter the vehicle. Either modify what you have, use an aftermarket solution, or have a 3D printed version made. Good luck!

[@ORLANDOBUSA]

@@InJasonsGarage ok thank you, will keep searching!

[@qu_0001]

Don’t we need any ventilation for the fan of the led?

[@InJasonsGarage]

Not necessarily. It depends on the materials used in the dust cap and the heat output of the light. OEM halogen bulbs are 3+ times hotter than an LED light. Check out the following links for more info.... www.youtube.com/@carlightreviews kzbin.infoH8VP762ApdA

[@trevorbelmont4633]

This is why 3d printers are so practical...

[@InJasonsGarage]

I love mine. I got a Bambu X1C recently and use it often.

[@trevorbelmont4633]

My Prusa mini was so helpful.. but of course it has it limitation for it having a small print bed..

[@keithbartlett7679]

The stock Colorado caps look larger than the GMC Terrain caps. I have a 2013 Terrain and those caps are virtually flush with the rear of the light housing. Options are very limited with that style dust cap.

[@KDlGG]

Take the cap off, dust caps aren’t needed for LEDs

[@andresloth]

Hi. I left the heatsink outside the rubber cap. Are there any issues?

[@InJasonsGarage]

As long as the cap is watertight, you should be fine. If not, you need to do some more mods to make it so. You'll thank me later. 😊

[@andresloth]

@@InJasonsGarage I mean, I'm pretty sure the fan is going to get wet and dusty cause the cap originally has a hole so the halogen bulb can be connected. The fan is sticking out that hole.

[@InJasonsGarage]

@@andresloth What vehicle?

[@andresloth]

@@InJasonsGarage Nissan tiida HB

[@InJasonsGarage]

@@andresloth Ok, sorry that IU am not very familiar with your vehicle. However, what I will say is that dust caps are important to keeping junk out of the capsule and that is not the job of the actual headlight bulb by design. So if the caps are weathertight with your headlight upgrades, I would think you will be OK.

[@SecretSquirrel28]

I just put Alph Rex Pro headlights in a 2015 tacoma. Need to get extended dust caps to fit LED headlights but unsure what size to get. Any tips? Thanks!

[@InJasonsGarage]

I wish I could tell you but I am not familiar with the Tacoma size. Try measuring the stock dust cap and find the closest extended cap size to it. Sorry I couldn't help more!

[@eduardocontreras1976]

Did you ever find any dust caps? I’m looking for some for the same alpha Rex pros

[@SecretSquirrel28]

Sorry for the really late reply. I ended up making my own. I got a set of the "universal" dust covers with the sealed back (no opening for wires). I think they were some weird brand name like Koomtoom or something. They are a soft silicone material that you can cut down to the needed diameter. I used a hole saw and cut out the center of the alpharex dust cover. Then cut the covers I purchased to the correct diameter, made slits to accommodate the tabs on the alpharex covers. Then used high temp silicone to bond/seal them together. Make sure to use a high temp silicone. It worked really well. No leaks, no heat related issues from the LED fans. Hope that helps.@@eduardocontreras1976

[@gagt3400]

Nice, but what about the added length of led bulb wire and decoder box.. hmmmmm??

[@InJasonsGarage]

In most cases they get tucked into the headlight assembly behind the headlight unit when it is installed. How much space is available depends on the vehicle, but some headlight unit drivers are smaller than others. Check out carlightreviews.com for testing and reviews.

[@J-on-that_bike]

I think I damaged the rubber on my dust cover trying to push it in

[@InJasonsGarage]

The light blue gasket?

[@raghuram843]

Please share link for buying those dust caps

[@InJasonsGarage]

It is in the description: kzbin.info/www/bejne/rJaqd3ikm5ihebs

[@goltzhar]

G-man making a comment.

[@leecowell8165]

Why do you think these LED's have fans? It wouldn't be because they circulate AMBIENT AIR, would it? You may notice that halogens do NOT have circulating fans now why is that? well it so happens that those fans circulate AMBIENT air around the lenses to help contain temperature thus I would think you wouldn't wanna defeat the purpose of the fans to begin with. AND of course IF you completely encapsulate them that's exactly what's gonna happen. those caps need to be vented so once a year or so remove the VENTED cap, LED housing and give the reflector housing a big squirt.

[@InJasonsGarage]

LEDs have fans because they have components inside the core that need temperature regulation. As electronics (and more specifically LED emitters) increase in temperature, their output and longevity is reduced. Then fan's purpose is to draw the heat away from the emitter so it remains bright and doesn't burn out due to overheating. And since you asked...halogens do not have a fan because they don't need to be cooled. Technically, the hotter they get...the brighter they get. Halogen bulbs can reach 1,000 degrees f at their hottest point, where most LED bulbs reach no more than 1/3 of that at their hottest point. The cap is designed to keep dust and water out of the assembly so putting holes in it and/or removing it to spray water in there is a very bad idea. There is a reason that they are typically water tight. It keeps junk out of the housing, which is also often ventilated inside and under that dust cap seal in key spots, and if so...the LED light fan does indeed exchange air via those ventilated areas.

[@mirkolazar9250]

119 bucks for caps lights 75 bucks 😂 tf

[@InJasonsGarage]

If you wanna do it right, it comes with a cost. You can always do what other people have done, like I mentioned in this video.

[@TrevorPhilipsBro]

Universal headlight cover?

[@InJasonsGarage]

I have heard they are hit and miss with sealing correctly and securely.