Headlight Upgrade
HB4 / 9006 to HB3 / 9005 Conversion
Overview
Many people find the standard FTO headlights to be quite dull. While there are many aftermarket bulb upgrades, one of the cheapest and most effective is as simple as replacing your low-beam globes with high-beam globes.
As with many cars, the FTO uses HB4 / 9006 globes for the low-beam and HB3 / 9005 globes for the high-beam. HB3 globes produce around 70% more light than HB4 globes while only using an additional 10W of power. Some bulb manufacturers are now making HB3 globes with a halogen / xenon mix which increases the brightness by around 30%. When you compare the cost and brightness of the HB3 and HB3 +30 globes to other alternatives such as HID kits, they become a very attractive option.
HB4 - 1,000 lumens, 51W, $20
HB3 - 1,700 lumens, 60W, $20
HB3 +30 - 2,200 lumens, 60W, $30
HID - 3,000 lumens, 35W, $500
* Light output and cost are approximate and will differ depending upon brands and models.
Most cars use reflector based headlight systems, and if you were to replace the low-beam globes with high-beam ones it would cause issues. Reflector based headlights have less control over the distribution of light and for this reason the connectors on HB3 and HB4 globes are different so that you don’t accidentally put a high-beam globe in a low-beam socket. In a similar manner, normal low-beam globes have a coated tip to minimise glare from reflector based headlights.
With the FTO, the issue of glare and stray light is virtually eliminated through the use of projector based headlights. The advantage of projector based headlights is that they focus the light much better than reflector based headlights, creating a very precise light distribution pattern. They also have a cut-off which prevents stray light from dazzling the oncoming traffic and cars in front of you.
Process
The HB3 and HB4 globes look almost identical, but they have been designed so as to prevent you accidentally putting them in the wrong socket. To overcome this issue there are three modifications that need to be made to the HB3 globe so that it will fit in the HB4 socket.
Flange
The flange of the HB3 and HB4 globes are mirror images of each other. To allow the HB3 globe to fit in the HB4 socket, the centre flange must be trimmed. Do not completely remove this flange otherwise the globe can come loose.
Connector
The connector on the HB4 globes is keyed with a single ridge, while the HB3 globes have two ridges. By removing the two ridges, the HB3 globe will then fit in the HB4 connector. Even without these ridges the globe is still held firmly in place by the locking catch. The ridges can be filed down or cut out.
O-Ring Seal
Although the HB3 globe has an o-ring seal, the size of it is smaller than the HB4 o-ring seal. To resolve this, simply take the o-ring seal off your old HB4 globes and slip it over the top of the HB3 globe. This o-ring is needed to ensure a proper seal, without it the globe will sit loose and possibly wobble out.
Alignment
In the process of replacing the globes you may have altered their alignment. It pays to double check this and if necessary rectify the problem. Even with the projector headlight cut-off, if the light is angled too high it could shine into the eyes of oncoming traffic or those in front of you.
Before taking out your old globes, it could be helpful to mark their position on a wall with a piece of chalk. Then when you put the new globes in you can ensure the new ones are aligned the same.
Result
The result of this modification is outstanding! The light produced is very bright and makes a huge difference.
Driver’s side globe is a HB3 +30% while the passengers side globe uses a standard HB4 globe.
really good point - take note!RichardH wrote: It's worth noting that at no point in your hacking, filing, swearing frenzy of globe modification should you lay a finger on the actual glass bit. If you do, there goes any hope of the globe lasting any length of time. It has to be totally untouched, with no oily fingerprints.
It will be pretty hard to avoid touching the globe, so get yourself some isopropal alcohol, it's the stuff they use in cleaning fluid for cassette and VCR cleaners. I bought a pack of 5 isopropal alcohol wipes from Jaycar for around $4.00. If you can't get the wipes, just get some head cleaning fluid from Dick Smith or Tandy and put it on a VERY clean cotton cloth. Use this to clean the globes and remove any traces of oils that got on the globes from your skin.
Isopropal alcohol is a very thin alcohol and leaves no residue, hence this is why it is used for cleaning purposes. It is however HIGHLY evaporative. If you leave the wipe alone for 2 mins it's completely dry.
If I knew of that link I could have saved myself a lot of time! 
