I am currently in the drawing stage of designing a 100% LED headlight on my03. design so far consist of the factory headlight, and high beam housings removed and replace with a flat all black surface. on top of that flat surface is a printed circuit board using 10 rows of 5mm LED's. all of these lights will be amplified by 1 convex lens. the "low beam" will light up 4 rows and the "high beam" will light up the last 6 rows. in theory this should be very bright but as we all know things dont always work out like we plan. Electric guys let me know if there is something that i have missed in this design.

 

I would take a look at existing LED headlight modules that are currently in use on OEM designs and some aftermarket ones to see how they are set up. One thing you have to have is the cooling. Even the 5 and 10 W LED replacements for home lamps have heatsinks to keep them cool. The heat from the headlights are likely to be more and they are sealed in. This is going to determine the spacing available. The other issue LEDs have is the directionality, they are spec'd out with various viewing angles.

 

so i would have to have them mirrored all the way around? a cooling fan shouldnt be an issue to install, i would just use a small one from a PC

 

I assumed LED's run cooler than HID's no?

 

any pics of your design that youve made. curious to see the placement of the LED's

 

i dont have any pics yet because i am just currently in the sketching phase. I was on guard duty yesterday guarding this old camp out here in iraq and i came across some LED flood lights so i am currently studying up on the circuit boards, the diodes, and the individual magnification of the lights. pretty amazing stuff taking a small efficient diode and taking a crystal clear sphere with a clear diamond shape housing could be so bright. but im still drawing out the design as far as light placement.