For anyone who might be interested in an alternative headlight dust cap extension. This allows substantially more room than some other methods and isn't a lot of work if you have the tools and are handy.
Also, proceed at your own risk.
I've recently started trying out some LED headlights, just because I enjoy trying out new things that I may find useful. In the process, as many know, the GM projector (and halogen high beams for that matter) have a dust cover over them. When converting to some HID and many LED H11 headlight replacements, the GM dust cover makes for a tight fit if it can be still used at all. So, I endeavored to modify the GM factory headlight dust covers to remedy this.
I wanted a decent looking outcome without spending a lot of cash. After trying various off the shelf "parts", I used the ever helpful process of "thinking outside the box". I purchased 4 GM dust covers for about $9ea which are used on many new GM vehicles:
Part No.: 23486492 COVER ASM-HDLP BULB ACC
I purchased these both to have potential spares for my other vehicle or in case I needed a sacrificial prototype. . . In other words, buggered one up. But all went well and I made a couple pair. Of course, you can always just mod the ones your vehicle comes with and save $$. The only other items I needed were the "Custom Dust Cover Extensions" and some adhesive sealant to secure them to the GM dust cover after a bit of manicuring.
I initially tried some smaller diameter extensions and found it too much trouble to implement since the H11 bulb does not sit centered behind the GM dust cover. Therefore, I opted for a dust cover lobotomy and removed a good portion of it that yielded a lot of potential room. This leaves very adequate space for HID wiring/connectors, etc as well as the bulk of LED cooling apparatus be it cooling fans/fins or those braided wire strips. The pictures show an unmodified GM Dust Cover and the result after using a 1.5" hole saw to cut 3 overlapping holes into the top and then a Dremel to finish out the rest. It also helps to true up the plastic drain cover edge by using a sanding block or belt sander, as well as trimming some flash off of the edges and surface with a utility or Exacto blade. I am also thinking of adding a few ventilation holes with filter media behind them to allow more heat to escape from the bulb housing. The filter media will keep most dust out, but allow air to move through.
In all, the "Custom Dust Cover Extension" cost less than $2 each plus a little adhesive. I happened to have and recommend some automotive Goop brand adhesive which works well. It adheres to most plastics.
I am using some H11 LEDs which I will post here and are working very well. They are the best for the $$ I have found unless I wanted to spend +$80 to $100 or more. And these seem to have both a good low beam pattern as well as lighted distance ahead of the vehicle. There are a few that are slightly better, but then it is in the higher price range as mentioned. I found the H11 LED headlights I used for $35 the pair on 'Zon when they had a coupon price. Normally about $50. https://www.amazon.com/gp/product/B01MXMIRY6/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1
By the way. . these H11 LED replacements require no capacitor or other wiring to remedy DRL flickering. They are plug and play.
2017 LED Headlight Reviews:
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In reading the LED reviews, be mindful that things vary depending on the bulb type they replace. . H11, H16, 9004, 9005, etc. I noticed in the review listed here they use a 9007 replacement. The beam pattern on the H11 LED I bought is much better than shown in this review, and this Simdevanma LED H11 still comes up as #2 in Best for 2017 as tested in this review.
Prinsco Model EC03 3" drain cap.
Prinsco Corrugated End Cap (Prinsco 1841323), Drain Tiles | Home Improvement | Theisens.com
NOTE: I need to make a disclaimer. If you do not find this useful and not your cup of tea, that is OK with me. I do not need or want negative critics. I state this because at times, things are not appreciated by some.