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These headlights suck worse than a Hillary presidency. Most of the upgrade options I see in the tech folder deal with the later models. What is the best option that doesn't involve cutting of the header?
You have options, Do some research.
I am currently correcting the previous owners after market one piece replacement lights which didn't even fit the opening. Instead of cutting the existing header, I ordered the 2005-2007 header, and the 2005-2007 headlights from Ford.
From there I will be opening the new headlights and outfitting them with projector LED's, projector HID's are an option too. You could always order the work truck headlight parts as well, and install an LED sealed beam unit as pictured.
I installed the 2003-2004 style units like the truck...^^^...above on the right in the wifes Excursion. They are a direct fit and much better light. I installed the same on my F350 in a smoked lense and I hate driving the thing at night...which isn't much thank goodness.
In conjunction, I installed the 2005-2007 front grilles on both trucks. You have to trim the bottom a little, but it's a better look.
i just replaced the oem bulbs in my 2006 and 2011 trucks with LED bulbs. Both simple plug and play. Huge improvement.
Prior to doing that, I adjusted my 2011 headlights aim, which I had never done. They were a little too high, so there was some improvement by lowering the beam a bit.