Hey all,

Here's a weird question. lol. Backstory...my car came with aftermarket projectors (H1 bulbs). Low was an old HID with old ballasts, high was an old multi-chip H1 LED. Both were less than impressive; the low was barely adequate in city driving with a lot of ambient light, and you almost couldn't tell the highs were on at all. I addressed the low beams with an updated HID ballast, new lenses, and new H7 bulbs, and they are at least acceptable now - but the high beams needed serious help. After trying several different bulbs, I eventually decided to build my own high beams. If they turned out poorly, it was less than $300 to replace the very worn, heat-warped plastic projector bezels and hazed over covers. The high beams are now 100W LED chips on 80x80mm heat sinks with cooling fans, running with a 12V to 35V driver on each side.

My question is this: below is a picture of the driver. I don't necessarily need to completely seal it off from the elements and make it submersible to 20 feet, but I also don't want to just stick it to the headlight frames with double-sided tape. I'm trying to think of a simple way to "package" these drivers, maybe by re-purposing some sort of readily available plastic case (something I might be able to buy at a hardware store or Wally World and trim with a Dremel to put the driver in), then I can stick the case to the headlight frame. Does anyone have any ideas on how to package/seal/mount the driver board? The headlight frame sits flush against the car so I can't through-bolt it. Let me know what you think! TIA!


Kinda reminds of the Terminator. "I need your clothes, your boots, and your motorcycle..."

How would you package/seal/mount this driver board?

Planning to stick it here, but what can I enclose it in?

 

I would use these project boxes and then 3m double sided tape them where ya want. Drill holes and use rubber grommets for the exit of wiring and you will be good to go. Heat buildup should be considered however. They come in many sizes and the rubber grommets are easily found on amazon as well.