Finally finished my headlight projector retrofit (LOTS of PICS)

[jasonlmarsh]

This was my first attempt at retro'ing a set of headlights, so it is a pretty simple & cheap setup. I tried to stay on the cheap with everything, just in case I screwed it up...

H1 mini's I scored on Ebay for $50. I painted the shrouds satin black

Projectors installed in the reflector. I had to do a little dremel work in the bulb socket area to get the projector to sit properly.

Mounted up, about ready to reinstall the lenses. Fortunately I had a fairly new set of aftermarket headlight assemblies. Removing the lenses was super easy, 10 minutes @ 200 degrees and they pulled right off.

Lenses are back on. While I was in there, I decided to throw in a set of $20 Autozone white LED's to use as DRL's

Here they are with the DRL's lit up.

Output shots:
For comparison, here's my wifes Lexus RX350 low/high

Here's mine with 35w HID's @ 5000k

And mine again with 55w HID's @ 5000k

Now I just need to figure out what to do with the fogs. Currently I have a set of 35w @ 3000k HID's in the reflectors.

 

[rburch]

Looks great!

Good job!

 

[tallsville]

looks good. why not try a set of the minis in the fogs

 

[rayt]

looks good. why not try a set of the minis in the fogs

minis will not fit the fog
i retrofitted my fogs with matchbox projectors that were available for a limited time.

 

[sgtowing]

Looks great. Wanna do mine?

Sent from my Galaxy SIII Using Tapatalk2

 

[Captain Morgan]

This is what I've been looking at doing and have emails to TRS and some housing resellers.

I think this will end up being the best compromise in cost and quality.


.

 

[jasonlmarsh]

Thanks guys! I agree the mini's would not fit in the fogs, they are about 5.25" length and the fogs are only about 2" deep. So I'm going to have to find somethig that can be exposed to the elements on the back side. I'm trying to decide between Ford Fusion, Hella DE, or Blazer's.

 

[RI-Matt]

Jason the headlights look great but I was wondering what it would look like with the chrome reflector housing blacked out too as it's not needed anymore with the projectors.


Matt

 

[jjbusa]

Tight work

 

[FisherPete]

Excellent step up! Nicely done.

Now you've got me thinking!

 

[DF5.4]

Those look great! How is the light out on the road?

 

[Captain Morgan]

So I'm going to have to find something that can be exposed to the elements on the back side.

Not if you buy some PVC pipe and cap and flange and make a housing on the backside for support and seal.

 

[jasonlmarsh]

Jason the headlights look great but I was wondering what it would look like with the chrome reflector housing blacked out too as it's not needed anymore with the projectors.
Matt

Yea I was originally going to paint the reflector black and leave the projector shroud in chrome, but the condition of the chrome on the shroud was not good enough to keep. I also considered doing the reflectors in white, with the black shroud, in sort of a "Storm Trooper" look (I saw a set on the Dodge Ram forum and they were sweet), but I decided not to bother with it at this time.

 

[jasonlmarsh]

Those look great! How is the light out on the road?

Awesome! So much better than the factory reflectors (even with HID's). Reflectors with halogens = crap... Reflectors with HID's = decent.... Projectors with HID's = Incredible

Oh and when I throw on the brights, it lights up the whole freaking street. I'll try to get a lowbeam/highbeam pics of a neighborhood street at night.

Not if you buy some PVC pipe and cap and flange and make a housing on the backside for support and seal.

I hadnt thought of that, I need to start thinking on that a bit.

 

[Georgethomas]

looks good. why not try a set of the led lighting minis in the fogs

Just gorgeous man. i am looking for such led lights.

 

[rwmorrisonjr]

Looks really good! I've got some questions:

• 
  1.Did you have any problems with the horizontal aim of the lamps? My right one seems to be more to the right than straight ahead, but maybe its just the way the housing fits on the truck. Also,
  
  2. Did your housings fit the same as they did before you heated them? Neither of mine fit perfectly in the openings in my opinion (RT one seems to sit back on the outside, LT sticks out a little in the lower corner by the grill), but that might just be my perfectionist side coming out!
  
  3. When you aimed them, what measurements did you use?

Just trying to get these things perfect, it shouldn't be as hard as I'm making it!

 

[jasonlmarsh]

Looks really good! I've got some questions:
1.Did you have any problems with the horizontal aim of the lamps? My right one seems to be more to the right than straight ahead, but maybe its just the way the housing fits on the truck. Also,

I think it's the way the housing is on the truck. My right headlight cutoff is also a bit to the right as well. The projectors are bolted to the reflector and the way the lock nut secures the projector, it forces the projector to be aligned with the original bulb socket.

2. Did your housings fit the same as they did before you heated them? Neither of mine fit perfectly in the openings in my opinion (RT one seems to sit back on the outside, LT sticks out a little in the lower corner by the grill), but that might just be my perfectionist side coming out!

I'm using aftermarket housings and they fit fine, however both of them had broken off the metal clip on the rear. I JB welded the clips back on while I was in there and they are holding up now. You might make sure the clips are fully seated in their sockts. Also, I think you can bend that bracket behind the light (the bracket that it clips into). So it could be out of alignment. Actually that might be why we both have a little bit of horizontal aim issues. Maybe we both should look at that...

3. When you aimed them, what measurements did you use?

A big brick wall. I saw where my wife's RX350 cutoff was, and set mine to be the same. Also got them as level as possible by aligning the cutoff with the bricks horizontally.

Just trying to get these things perfect, it shouldn't be as hard as I'm making it!

LOL, yes being a perfectionist can be a real monkey on your back. I have the same problem.

 

[SOLISIMO]

cant you do an led replacement for the fogs like they are doing with the raptors?

 

[jasonlmarsh]

That's a possibility. I've looked a little at LED's for other things, but haven't really thought about them for Fogs.

 

[jglopic]

That's a possibility. I've looked a little at LED's for other things, but haven't really thought about them for Fogs.

The issue with LED fog bulbs is whether or not you want to use them for light or for looks. All the LED fog light bulbs I have seen aren't full-brightness replacements, but are just used for style and color-matching to HID headlamps.

However, if you don't need the light output, it can be a lot cheaper than going HID for the fog lights!