Done the wiring upgrade, bulb upgrade and now LED bulbs. All steps imroved the light output but I'm dissapointed with the beam pattern of the leds, poor cut off and plenty of scatter. Anyone tried the extremly expensive options as used by Land Rover Defender from Nolden, Trucklite or JW Speaker?

If you have poor cut off and plenty of scatter, the problem is with the headlight lens, not the bulb. Over the years, the headlight lenses take a lot of abuse from grit and dirt from the road which really micropits the glass and causes the light scatter and loss of focus. Also the mirroring gets tarnished over time and this doesn't help.

I replaced the sealed beam units on my 924 but kept the same bulbs and was amazed at the difference - they were brighter and with a really sharp cut off. Obviously you can change the bulbs too.

Yes there is a case for lens replacement when they become pitted and "shot blasted"and is a matter in it's own right, however this discussion is mainly concerned with the light source, many of us are upgrading our outdated driving lamps with a variety of different products, including LED, and several of us, despite considerable investment are suffering cut off and scattering, which is a feature of many LED's.