Extended dust cover for alpharex pro?

Just got these GTR ultra 2's today to put in my 2.5 gen alpharex pros and love the output. I'm able to get everything in the housing but it takes a little work to get the dust cap on and I'm worried about choking off the fan and having heat issues( premature bulb failure, melted housing)

Is there a deeper dust cap I can order?
Or
A way to modify the existing while staying watertight?

Also it safe to have the driver stuffed in the housing or could it possibly melt wires or the housing?

Appreciate any help! First set of LED bulbs or headlight housings I've ever bought for a vehicle and want them to last.

 

I'm literally in the same boat. I dont have a solution but ive tried searching on ebay for a replacement that will give room. The current cover will certainly choke out the LED. I got it to fit but probably not good at all for the LED and even the housing. I smushed it hard.
Im considering 3D printing some at my local public library. I also searched for rubber boot options but I really want to OEM feel.

Last option is to buy a holesaw and make a cutout, buy a PVC dome and JB weld it to give room.

Any other ideas?

 

This what I decided to do... Used a 2in holesaw to cut a hole in the cap and squeeze it in. That double lip seals up nice around the cap and haven't had any issues.

Just a heads that it may void the warranty if you have one

https://brisource.com/products/rubber-dust-caps

Edit: just seen the comment about rubber boots... But that was my solution. Can take a pic of them installed if you'd like to see what it looks like

 

thank you! i just ordered them Alpharex should really offer something like this

 

No problem dude glad I can help! I definitely agree or some should 3d print some deeper caps but this is the best solution I could find and definitely didn't wanna burn up $200 bulbs lol

 

Were you guys able to get the dust cover on completely with the Ultra 2?

Retrofitsource just suggested I get the GTR CSP Mini bulbs instead and they would fit better. But I need good light output, these halogens suck!

 

Yes I was able to get the cover on but was no room behind the fan without the extension and was worried about burning them up and liked the output so didn't wanna mess with returning them

 

Hmm.. I might have to do this too. Does the Ultra 2 put out twice the brightness in your opinion? These Pro bulbs really suck!

 

Yeah those halogens are almost worthless... Yeah probably at least twice as bright but I'd hate to mislead you on it because had them awhile now.

I took a picture and video before I changed them so let me finish this job and I'll post a comparison up for you

 

Ultra 2 bulbs on top... And halogens on bottom. Quite a difference looking at them side by side

 

Yeah that looks a hell of a lot brighter! Thanks for the pics. Going to make a purchase, everything is 20% off on retrofitsource for Black Friday fyi.

 

Well unfortunately I went with the GTR CSP Mini’s and they do not fit the AlphaRex Pro’s.
The LED tip is too large to enter the projector.

 

I'll be following in your footsteps. Looks like Amazon also has a cap extension similar to the one you used. I just ordered them:

$10 VekAuto 2 Pcs Car Headlight Housing Dust Seal Cap, 54mm Universal for Aftermarket Headlamp Xenon Light LED Retrofit Durable Rubber Black

https://www.amazon.com/VekAuto-Head...fix=headlight+rubber+dust+cap,aps,207&sr=8-12

 

The ultras are a tight fit into the projector too but will definitely fit with a little work. Yeah those look pretty similar just drill the hole about 2" and squeeze it in for a tight fit. I haven't had any moisture problems but could silicone it also if you wish