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Old 07-10-2000, 03:05 AM   #1
IMPBOY
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Post To those with Hella 500s, please help

I'm thinking about getting the Hella 500 driving lights. How's the installation? Do I need to drill any holes on the bumper to mount the lights? How did you guys wire the lights? Any tips or wire diagrams will be appreciated.
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Old 07-10-2000, 04:56 AM   #2
Tony
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I'm working on doing the same thing. I've almost got it done. Unfortunately you'll need to remove the front bumper cover to get at the mounting plates for the fogs (I assume that's where they're going). Basically what you're going to do is get some mounting plates (DIY or give Rallispec a call) and they will bolt to the Hellas and then the whole assembly is mounted to the bumper using the three foglight mounting holes. The reason you have to get the bumper off is to take out the plate that the fogs mount to and drill a hole big enough to allow the light stud and bolt to pass through.

For wiring the way it should be wired is to have it switched with the highbeam circuit. This way you'll have a master switch for the lights but once that switch is on the lights will only come on when you switch on the highbeams. This is safer too since you can turn them off quickly and aren't fumbling for some switch. If you go to the Susquehanna Motorsports site he has the wiring diagrams but the Hellas should come with a diagram also. ( http://catalog.com/susq/index.htm )

Tony
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Old 07-10-2000, 05:07 AM   #3
BoomerRS
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i was going to put on some hella 500s also (MY98 bumper btw)
tony why would you only want yours on if the highbeams are on? if they are aimed correctly they are legal (varies from state to state i think, i know in CT you can have up to 4 forward facing lights on at one time)... is that just a preference?
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Old 07-10-2000, 05:26 AM   #4
Tony
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Have you ever seen Hella 500s at night? They're about ten times brighter than your highbeams. I don't think there is anyway to have them pointed (except maybe straight down) that wouldn't burn the retinas out of other drivers. These lights aren't the best off road lights out there but they are way too bright to use in traffic. They are strictly for off-road use or when you are absoulutely sure there isn't anyone else on the road.

There is a fog light lens pattern you can get for the Hella 500s and with those pointed down where fogs are supposed to be you might be ok in traffic.

As for mounting them to a MY98 bumper, I don't know how you could do it other than to use a light bar.

Tony
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Old 07-10-2000, 10:08 AM   #5
Ken
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Are the Hella 500s you guys are talking about come in a driving configuration as you describe (ie: clear lenses)? The kit I have seen has the yellow lenses for fog, but I presume they bolt on the same way? Please post some Hella part#'s if you've got them handy!

So you're saying that the OEM fog light brackets are not needed right?

Thanks,
Ken
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Old 07-10-2000, 10:19 AM   #6
Tony
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Yes, they come in clear driving light configuration.

You will need you OEM brakets. That is what you new brakets will mount to.

I don't know the PNs but you can pick them up at Pep Boys (or similar auto parts store) for $65.

Tony
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Old 07-10-2000, 02:11 PM   #7
BoomerRS
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oh i see, you are going to put on the driving lights not the fogs. duh. that is going to be cool.
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Old 07-11-2000, 06:23 AM   #8
Bob OM,Md
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Lightbulb

I just completed installing Hella 500 CLEAR FOGS on my '99 Forester. And I relied on the useful information I got from this website. See earlier postings (May and June). My lamps can be switched on and off independently of the headlights and/or OEM foglights. As fog lights, they are aimed, as the instructions say, just about 4" below the headlamp line at 25'. The do a great job and filling in and provide side-to-side dispersion of light that I find useful. No oncoming vehicle has yet blazed brights at me, so the beams do not seem to bother others. I don't know about the attachment of the lamps to the bumper because I mounted mine to a Mannik grillguard.

But about the wiring? I used the wiring harness that the Susquehanna Motor people supplied (and was Ken Beard helpful!) I ran the doubled hot wire from the lamps to the relay along the left side of the engine compartment, behind the windshield washer. The ground wires from the lamps (which I had to supply myself, not included in the light kit), ran from the bulbs to the grounding terminal on the frame at the front of the engine compartment, just opposite the battery. There were already Black/Yellow grounds there and the bolt had a star lock washer (for better metal contact, I assume) The Hot (red) lead from the relay went to the + post on the battery (there's already another bolt on the post which can be used. The ground from the relay went to the grounding terminal on the left strut tower (like the first one, it already has grounds attached and has the star lock washer). The switch line went from the relay through a hole (about 2" in diameter) just above the carpet line on the inside, just above the brake and clutch pedals. It is just under the brake master cylnder assembly. I ran a straightened out coat hanger through the opening from the *inside*, located the hanger in the engine compartment, attached the switch wire and gentled pulled back inside the vehicle and onto the switch. Be careful not to damage the rubber seal plug that closes up that hole.

Now, to the supply wire. That line was supposed to be tapped into a line that was hot only when ignition was on according to my plan. To get to all those wires and connectors you must drop the under dash panel (see FOG LIGHT MOD on this site for great directions). Once that was done, I started testing lines with my little tester when lo-and-behold there was an unused female connector just taped to some other wires. It was hot ONLY when the ignition was on. So, in went the supply line. The switch ground lead went to a nice shiny bolt on the metal support piece for the dashboard --covered by the panel removed to allow access.

My plan was to have the switch placed to the right of the Alarm Status LED (where the OEM switches for Fogs, Wiper Defroster, Cruise Control and Alarm Status line up). BUT, because of that shiny metal support piece, there was not enough clearance to accomodate the rearward projection (about 1.5") of the switch. For about a week I had the switch hanging out of where the Tilt Control lever swings down. But this site came to the rescue again. The switch is now mounted on the lower left side of the steering column plastic housing. It was suggested that I remove the housing. I did so and very carefully determined where I could put a 1/2" hole that would allow the rear of the switch enough room to make the wire connections. Test, test, and test again to be sure. There is room, but be careful: if its too far towards the steering wheel you run into the turn signal release thing; too far away from the steering wheel conflicts with the combo switch. Also watch the height: as low as possible seems to be better. Once the switch was placed, the wires ran up along the left side of the steering column cover, under the groove where the tilt lever runs, just neatly tucked out of sight.

The lights have been working fine for the past two weeks or so. I hope this long description helps a bit and saves you some time and misdirected effort.
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Old 07-11-2000, 07:05 AM   #9
Tony
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Thanks Bob,
That was very informative.

BTW my comments on wiring to the highbeams was meant for people who were hooking up driving lights not fogs. I think for most people adding Hella 500 fogs would be a better route than what I want to do, since most people want them on all the time and that location isn't ideal for driving lights anyway.

Tony
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Old 07-11-2000, 07:55 AM   #10
syborg_97
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I installed Hella's on my 97 outback sport- I mounted them on top of the bumper (between the headlights). Hella's install instructions indicate to drill a large hole right into the bumper- but I didn't like that idea, since the bumper is filled with foam, an you'd have to clamp up through almost 3 inches of material to mount the light rigidly.
Instead, I got some 2" wide, 0.090" thick Stainless steel flat stock, about 18" long, and formed two brackets that wrapped around the top section of the bumper. These mount with a through bolt in the back of the bumper section, behind the grill plate. Then the lights mount to the brackets. I put some adhesive backed foam tape on the underside of the stainless, so that they wouldn't damage the bumper finish. The set-up works great, since you can remove them without leaving holes in the bumper, and the whole thing is lower profile then mounting up a whole lightbar set-up.
As for wiring, I wired mine to the highbeams- one note on the hella relay- make sure you coverthe connections with tape (and silicone it too). Basically you want to make sure no moisture gets in there, since I've already had one corrode and stop working.
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Old 07-11-2000, 08:35 AM   #11
BoomerRS
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syborg
any pics?????? i couldnt picture it in my head from your description.
check out the new england forum... we meet monthly, sometimes more often, and of course OBS owners are welcome (rufan attends, and he has an OBS).
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Old 07-11-2000, 10:30 AM   #12
Ken
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FYI: I picked up the Hella 500 driving configuration lights for ~$105Cnd. Part#76110 for the entire kit. I can't wait to put these on...
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