How to mod a Denso ballast-56k warning

[pks485]

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.



Hopefully these pictures will help people modify their denso ballasts. This mod is hard because you have to work in such a small space but the results are amazing. Again, as usual, do this at your own risk. For off road use only. Enjoy!

Remove the metal screw and pry the cover off


You will need to remove the potting material to gain access to where soldering needs to be done. I have read on the forums that q-tips are good for removing denso potting material. Whatever works best for you.

(finished denso)


(close ups of area that you have to work with)

Solder the wires from the potentiometer to the resistors as shown in the pictures. Some people like to remove the resistors completely.



10k pot

[GOLFhid]

Your picture was help. But how can u solder so thick wire on top of that SMT.
Can you tell me what did you use as well.

Soldering the wire on top of that s still a myster

[haknslash]

Moved to the University.

[electric130]

results pics?

[pks485]

You can solder on top as well as remove the resitors. I did not mod these ballasts. This set was modded by member on this forum that charges for the service(almost $200+ the price of the ballasts ](*,) ) My ballasts died with in two weeks of getting the modification done. I rarely used these ballasts in boost mode. Maybe twice for 5 minute stretches. I even asked the seller if he had ever had any problems with any boosted ballasts going bad and was assured that he had never experienced a problem with these.

The seller gave me instructions on how to mod the densos. I haven't done it yet because I was able to mod bosch ballasts instead. I basically took pictures of the dead ballasts and wrote up the instructions according to the seller. Reverse engineering these will hopefully help members here do this modification on there own instead of dishing out major money to others.

I am a little skeptical every time a member of this forum talks about densos being so reliable when boosted. Maybe some others with boosted densos can comment about long term use. I guess 2 weeks isn’t really long term ](*,) . I feel that no matter what kind of ballast you boost you are risking a good set of ballasts.

[CoZZm0_AU]

what is the value of the original component or the value of the pot that is used to replace it. Also is it linear or log pot?

[pks485]

what is the value of the original component or the value of the pot that is used to replace it. Also is it linear or log pot?

I added some pictures of the 10k pot

[paketa1]

Only strange people would use that wire to solder ( what a mess ) !!!

[Cracky]

excuse my ignorance but what does this mod do specifically?

[CoZZm0_AU]

Increases the potential power output of the ballast past the factory 35W to up to as high as the ballast circuitry might go, which has been reported as high as ~100+W in previous threads, although the heat produced at such a high wattage is just amazing.

Most people run them to 50-70W, which overdrives all the electornics and the globes, but produces a FAR brighter output.

Its a risky modification as it can cause damage to all the components in the HID setup, but some people just can't get enough Lumens!

[Cracky]

ah. figured it was something like. Thanks for explaining it.

[bmxpert57]

Im sorry I cant really make it clear where to solder the big black wires are in the way. Is this correct;?

[RotaryRasp]

How do you know what resistor to use? Can we get some more detailed pics. I have these ballasts and I'd like to run them at 40-45 watts.

[superjoe83]

How do you know what resistor to use? Can we get some more detailed pics. I have these ballasts and I'd like to run them at 40-45 watts.

have you popped the cover off of yours and seen just how small the parts are? i got one denso ballast a few months ago to put in my spotlight, and i had previously seen pics of them modded, well i opened it up, looked at it a bit, then put the cover back on because unless you do some kind of miniature electronic work for a living, your most likely going to screw up a good ballast, i did however get some Bosch gen1's and modded them, the Bosch ballasts are much easier to work with, good luck!

[ZOMGVTEK]