Remove the headlights and taillights.
Some light assemblies have a sealed housing. Use a 1" hole saw to make a hole closest to the center of the reflector. For maximum illumination, use TWO strobes in each headlight.
Whelen mounting diagram shows best strobe positioning.
Use the strobe flange to drill a pilot hole into the plastic housing. This keeps housing from cracking.
Positon the gasket over the flashtube/strobe unit.
Use the self-tapping screws to secure in the opening.
Place a bead of silicone sealant around each strobe unit.
Make sure there's plenty of sealant used. You don;t want water getting into the headlight or on the flash tubes.
Some headlight housings, like those on newer Ram pickups, requires cutting a panel out of the back of the plastic headlight assembly to access the headlight reflector housing. Cut carefully.
Use hole saw and a vacuum to keep the plastic shavings from getting into the headlight reflector. Note TWO mounting holes.
Each mounting hole is close to the center of the upper and lower headlight reflectors.
Install the flashtubes in the holes.
Use the self-tapping screws to hold strobes in place.
Ram headlight install should look like this when tubes are properly positioned.
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Place the plastic panel you removed earlier back into position. Use a soldering iron to "weld" it in place.
Push the tip of the soldering iron lightly into the plastic so it "stitches" the two pieces together.
Run a bead of 3M butyl mastic tape (windshield sealer) around the welded seam to seal.
Press and mold it. Doesn;t look pretty--but no water is going to get inside the headlight.
The finished headlight hosing ready for re-installing and running wires to the controller.
How to install strobes in late-model Ram truck headlight/taillight housings
One of the best locations for mounting strobes is in headlights and taillights because the reflectors provide maximum illumination.
Installing hidden strobes is simple enough: Cut the proper size hole in the housing, insert the strobe unit and run the wires to the proper location.
This is easy in most pickup headlight/taillight assemblies. But the later-model Dodge/Ram pickups have a headlight assembly that’s inside a second housing.
This requires a few extra steps to ensure the strobe is 1) mounted properly, and 2) sealed from the elements.
Allcomm Wireless in Birmingham, Alabama, install lighting systems on all types of emergency, utility and commercial vehicles.
An Allcomm installer took us through the steps needed to put strobes for a Whelen Hide-A-Way system, which uses HA230 flashtube-style heads, in the headlight housing of a 2010 Ram 2500HD. — Bruce W. Smith
