DIY Headlight Conversion from HID to LED w/ Custom Centrifugal Exhaust Fan (Acura TSX CL9)
The original HID (High Intensity Discharge) bulbs on my Acura TSX CL9 were glowing dimmer and treading end of life. Rather than replacing with new HID bulbs, I decided to convert them to LEDs for several performance benefits.
LEDs are more efficient by emitting more light per wattage. They can operate at 12 volts (typical vehicle voltage) and, unlike HIDs, do not require a high-voltage ballast that operates between 80 to 25,000 volts (for initial startup to excite the pressurized Xenon gas). By removing the ballast, I also save power consumption, footprint and weight on the headlight enclosure.
However, LEDs are sensitive to heat. LEDs begin to dim or fail at around 80°C at the heat sink junction. Thus, I decided to add an additional exhaust fan to extract heat out of the enclosure and circulate it with cooler ambient air. At room temperature, the enclosure maintains less than 35°C internal temperature and less than 60°C at the LED heat sink.