DISCLAMER:
Try this modification at your own risk. I'm not responsible for any personal injury/death, mistakes/long term effects and/or damage to property. Please be cautious, ballasts run at high voltage and can carry risk of death if altered by people. Please refrain from carrying out this modification if you are unaware of the risk involved.
(I have moved some pictures from later posts into this post to try and organize this better)
I have finally supercharged my Bosch AL generation 2 ballasts. Hopefully I can inspire some other people to try this mod instead of paying $400 to others to get a set of 70 watt Denso’s. It is easy as long as you have some basic skills:
1. Soldering
2. Ability to go to radio shack or other electronics stores
3. Ability to use simple hand tools
4. COMMON SENSE (As said by a member in an earlier post there is always an idiot who learns how to kill himself with a nine volt battery. If you are one of those people please don’t try this.)
Step one collect the necessary parts
1 100k dual ganged potentiometer
Wire (I used 20 gauge)
Solder
Soldering iron
Flux
Bosch AL Ballasts
Hex wrench set
Step 1
Remove the hex bolts on the ballast circled in red.

Step 2
Remove the board from the housing as shown in the picture. It is held in with glue/silicone. Pry it out with a small screw driver. It doesn’t take too much force. Make sure you don’t use to much force and damage the ballast.

Step 3
Locate the resistor number 2612. It is on the underside of the board. Solder two wires as represented in the picture by the black lines to the ends of the resistor. I used 20 gauge wiring.

Step 4
Wire the other ends of the two 20 gauge wires to a potentiometer. I used a 100k dual ganged potentiometer that I bought from radio shack for around $3. The dual ganged feature allows for 2 ballasts to be controlled by the same potentiometer.
Step 5
Close the ballast up and test your new supercharged ballast.
(My camera was borrowed by my brother so I had to borrow one image from copiertech)
Some side notes:
I have tested the ballast in my car for about an hour each time with no ill effects. The bulb does change colors at higher output. I have yet to measure the actual watts because I don’t have an ammeter yet. Hopefully I will have time to get one soon. To give you an idea the brightness is close to initial start up brightness. If you want to test how bright these ballast can get without buying all of these supplies you can. Simply connect a wire from one side of resistor number 2612 to the other side of the same resistor. You will not burn out your ballast. I tested mine many times this way. These ballasts are a lot easier to work with than Denso’s and who wants to pay $400 for a modded set when these can be supercharged by anyone. I have tested up to a 12 foot wire between the pot and the resistor with no dimming in output (ran out of wire).
Please don’t jack up the prices on these ballasts. This is a hobby. Let’s try and not spoil it for everyone.
Use this information at your own risk. I take no responsibility for damage to you property or ballasts.
Happy moddding!

New Pictures:
I covered one of my headlights so that the pictures can show how much of a difference just one ballast makes.
BEFORE:

AFTER:

BEFORE:

AFTER:

:tonqe:
Some more pictures of the actual modded ballast.



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