plastic headlights don't last a year in any of the western deserts....E. Washington and Ore. can kill a set in one summer

exhaust gases acids and pollution, road acids and salts also damage the surface

and IF there was any ozone from climate change? add that to the list

cheapest way to go is a set of high power high quality add on aux. lights....my Aero is beyond the point of a few more drill holes decreasing the resale value....the add ons will be moved to the next vehicle so i recover the $$$$
glass lens, stainless steel round lens/reflector housings

 

I installed some cheap fog lights under the front bumper. I used two of the big-flanged bolts that held the bumper cover from under neath, so I didn't have to drill new holes. The problem with under-bumper installation is that they get hit with all sorts of road debris. I've lost two sets so far. That's why I buy cheap ones; they're mainly for backups of the main lights in case anything should happen to them.

If my picture had come through, you would have seen 3 relays (hi, low, aux) screwed to the side panel by the battery, and a big lug bolted to the battery side of the starter relay to supply the high current power. I crimped three 10 gauge wires into the lug, coated them with solder, and then heat-shrink tubed them for weather protection. Each wire comes from an in-line fuse holder. They are not hermetically sealed, but they were turned facing down so that no water can get into them. The other side of the fuse holders have enough wires to form a small droop-loop under each relay; in case water gets onto them, they will follow the droop, and not find their way to the relay connectors. Then the high current wires are bolted to holes drilled into the connector spades on the relay. The switching wires are similarly arranged, but they're only 14 gauge with smaller lugs.

If possible, you might want to get some stone shields for your expensive lights. That's about the only place where cheap plastic covers belong, so you can replace them easily. I got some for the Bosch lights on my Aero, and some of those GT Styling headlight covers for the HIDs I installed on my Mustang. Somewhere along the line, something heavy struck one of the GTS covers, and fractured it to pieces. But the light was un-damaged.

 

I know its been a while but I finally ordered the kit. I'll let you know how it goes. I need to repolish the headlights too. Next on the lighting agenda, adding extra driving lights. Anyone here done this and what did they use. Where did they mount?

 

K, i bought the relay kit. It was very easy to install, and it made the headlights noticeably brighter. I recommend to every Aerostar own to get this, unless you enjoy replacing headlight switches and tearing into the dash to replace melted plugs and harnesses.
https://www.ford-trucks.com/lc/lc.ph...sdetail%2F1983

I still need to adjust the headlights.

Thanks you guys, I am very pleased

 

Glad it's working out. Still using normal halogens?

As for driving lights, not much help with mounting ideas here. I will warn that true driving lights are for high beam use only...many use driving and fog interchangeably. Sorry If I'm stating the obvious here.

When you find a suitable location and figure out a style/shape you want...don't waste money on anything under $50. I had some cheap $30 lights from the parts store before and they didn't out out half the light that my Hella 500's do (not an exaggeration). Even using the same type/wattage bulb.

For driving lights, within reason/laws, higher is better. If you want light to help with low beams, go with some good fogs. Low for actual foul weather use, or mid/low level for a normal low beam supplement. Same goes on price for fogs.

Many cheap lights give a wrong description of their beam pattern, buyer beware...

How much do you want to spend and which style (driving/fog)?

 

I went with Sylvania Extra Vision Halogens. I will NOT go for white or blue tinted bulbs, since they are actually dimmer.

 

Those Sylvania Xtravision lights are among the best buys as far as stock replacements go. Lots of light, good distribution, last forever, and cheap to buy. The next step up to E4 spec lights would be much more expensive for a small gain.

Erich is right about quality of lights; the cheap "driving" or "fog" lights generally aren't worth the boxes that they come in. Go with a reputable brand like Hella, Cibie', or Marchall. But be prepared to cry when they get smashed by road debris. Get stone shields if they're available.

 

IIRC, It was about $70 and provided a marked improvement. That's not a lot of money in the grand scheme of things and the results well justified the cost. So much so that I did the same thing to my Capri as well.

 

Where do you get them for $70? Who makes them? Is that for a pair?

I got my Bosch H4 housings for about $90 for the set; not much more than what you're referring to, but much more than the Sylvania XtraVision lights that I paid less than $30 for the pair.

I'm saving my beans to get a set of these lights for my 69 Mach I:

http://www.danielsternlighting.com/products/csr.html

Too bad they don't come in the 200mm rectagular version.

 

I bought them from Susquehanna Motorsports, however, it was about 3-4 years ago when I did. The prices appear to have gone up since, although they vary depending on which size lamp you're buying. Kits for the 200mm lamp that would be used in the Aerostar start at $85 now.

www.rallylights.com/hella/headlamps.asp