HID projector retrofit

[houlster]

Finally got started on a HID projector retrofit that I've been wanting to do for a couple years now.

Morimoto mini d2s 4.0
Replica Lightning headlights

First I wasn't sure if these would actually fit. I gather they *can*, but might touch the inside of the cover just barely & cutting some clearance into the opening of the headlight bucket is needed. I wanted to go a little further. I've noticed I like look of the FXR conversions better (where they cut the crap out of the bucket) vs the mini H1's that just plug in. I like projector & shroud to sit back deeper in the bucket as far as they can.

I placed my shrouds in the headlight bucket first, all the way back. Did some measuring, some head scratching, rooting through some PVC fittings and sooo...



I came up with this trying to minimize chance of mis-alignment from cutting the headlight bucket. I started with some PVC pipe fittings. These are 2" pipe x 1.5" threaded connectors & have a nice, flat, right-angle surface on the inside. Original, and modified / cut down.

I did this on my mini-lathe, but you could do this with a saw & flat sanding surface without too much trouble. Main thing to make sure is the inside flat of the big end is parallel to the outside ring of the small end. Pics make more sense...

This is how it'll fit. The adapter will be epoxied to the back of the headlight bucket using the original bulb holder surface to locate it while the epoxy sets up. Should be lined up well, just back about 3/4" from not cutting the bucket.

Big end is cut down enough that it can sit flat on the back of the headlight / bulb holder area and the sides just clear the rear of the bucket. This makes sure the new locating surface for the projector (back of the small end) is centered & parallel to the original bulb holder.

I used a little RTV to stick the adapter to the back of the headlight to hold it firmly in place. After drying, JB welded around it. That's enough to hold it in place, but I'll likely add a layer of epoxy / fiberglass over it all before I'm done.

Then used a 3/4" PVC cap with a hole in it as a guide for my hole saw. Just stuck a 1/4" rod in the hole saw & used the biggest one I had that was still smaller than the ID of my adapter (2" IIRC?).

Saw made quick work of the initial cut.

Sanding drum on a Dremel made quick work of expanding that out to my adapter ID. Top and bottom of the hole have clearance just being straight. I had to taper the sides out a good bit more than shown here to clear the projector body all the way around.

--Dan

 

[houlster]

Test fitting projector:

My shrouds are Apollo 2.0 flat sided. I really couldn't have planned a more perfect fit. They snap on with no twisting or side pressure and sit right up to the back of the bucket. No trimming.

I realize the only thing holding these right now is the adapter epoxied to the back of the headlight. I have a couple ideas to sandwich the bucket to improve that a little. More to come.

 

[z168]

good work - looks very stable. Love to see how it finally fits and the beam pattern of it

 

[ams2737]

That looks really good I can't wait to see the finished product

 

[Grind]

Ooh! I've got some new headlight ass'ys and projectors sitting on my workbench, while I ponder what to do about the shroud just touching the lens enough to prevent it from seating. Your method gives me hope. Thanks, mate!

 

[houlster]

I sealed up my ballasts today & started installing the wiring harness in the truck so I could test the projector alignment. I'm sure it's going to be good & well within adjustment range, but mostly wanted to check rotation.

But ran into a problem. The connectors for the harness & the ballast don't match. My "kit" was supposed to have everything I needed, but didn't come with any adapter/pigtail/connector that I could even splice in myself. At the very least, I need the molded connector that plugs into the ballast. Also realized I didn't get my Gore-tex patches either... so I'm kinda idle till I get ahold of the vendor & get the parts.

 

[Grind]

I realize the only thing holding these right now is the adapter epoxied to the back of the headlight. I have a couple ideas to sandwich the bucket to improve that a little. More to come.

I would think you've got it pretty well sandwiched there, with the nut on the back of the projector housing. With the pipe fitting adapter JB welded on, it's probably stout enough that any further additions would be overkill.

 

[juan214]

Looks good so far, will watch for your posts. Good luck

 

[whitelightning99]

I would think you've got it pretty well sandwiched there, with the nut on the back of the projector housing. With the pipe fitting adapter JB welded on, it's probably stout enough that any further additions would be overkill.

was thinking the same but never hurts "the more the better" but if he ever has to pull them back apart it's goona be really hard to do can't wait to see them done,installed and working would love to do this on mine

 

[houlster]

was thinking the same but never hurts "the more the better" but if he ever has to pull them back apart it's goona be really hard to do can't wait to see them done,installed and working would love to do this on mine

The projectors are pretty front heavy with the glass lens and there's a lot of leverage working on the threaded shaft at the rear. I was concerned that the ABS may eventually loosen up if it was just pinched under the nut, or even the whole adapter be broken away from the bucket with that much leverage. Just wanna make sure. Removal won't be a problem later on if I need to.

 

[houlster]

I got my halo rings mounted. The HD something something switchbacks from Diode Dynamics. Has amber turns & 2 different brightness of white (bright for DRL & dimmer for headlights).

Now for the extra support...

First put several coats of epoxy mold release on the projector bodies. Then mixed up some JB QuikSteel. This is a firm putty so holds it's shape pretty well. Started with a couple blobs around the opening...

The projectors have a tabbed washer with a notch. One per projector, but for this I used both for this step. One on the projector body first, then inserted it into the bucket, then the 2nd on the back followed by the nut. This gives a metal washer on each side of the ABS flange for this step. Just made sure it went in at the correct rotation, tightened it up pretty snut & let the epoxy set up.

After 15 - 20 minutes, loosened the nut, screwed on the capped nut (that goes over the bulb) and rapped it a few times with a hammer while pulling a little on the projector to get it to pop out & it looks like this:

A couple more blobs...

For the 2nd I manged to do it all in one step. Just have to work quick as this stuff starts to set up in 3 - 5 minutes.

So this makes a... uh... "saddle" I guess? Fits the projector body perfectly. With the inner washer removed the projector is pulled back into this saddle as the nut it tightened. It's on the inside of the bucket so it'll help pull the adapter and bucket together rather than relying on just the JBWeld to hold the adapter on the back. It also supports the projector a lot further forward than the nut so there's less leverage working on it. About halfway up the projector body. Make sense??

Test fit the cover. Hard to see, but there is a nice gap there. I'm guessing about 3/8" to 1/2". It'll be a little less when the cover's sucked in tight.

Looking down from the top...

I did get my missing wire adapters so I was able to test fit & try these out. Did a rough aim adjustment to try and make them match the old headlights. Still need to finish the wiring, but these are about ready to put back together I think.

--Dan

 

[USMCBuckWild]

That looks amazing!!

Phenomenal job!

 

[Grind]

Looks like a good build.

 

[MISTERgadget]

I absolutely love this. Can't wait to see it on the truck. The D2S 4.0 really made me regret my Mini H! 7.0 setup, redoing them like this is on the to-do list for sure. The buckets you made to recess the projectors are awesome and the Apollo 2.0 shroud is one of my absolute favorites, same with the DD halos

 

[houlster]

Thanks fellas. I'm wanting this one to look good. Been out of town and/or sick so haven't gotten much done. I did start to clean up the lights & get them ready to seal. I figured alcohol would be safe to use...

I'm not sure what the chrome is made of, but it doesn't like alcohol. Switched to Plexus & that did fine, but I managed to strip the chrome in a small spot on the bucket. The shroud I was working on got royally effed up. So, I painted them. I don't want a completely blacked out look so I left a little chrome in them where it didn't get damaged. Should have them sealed up this week.

 

[reece146]

Still looks good - I wouldn't sweat it.

 

[MISTERgadget]

That looks really good!

 

[Grind]

TBH, I think the black improves the look.

 

[gixer2000]

Anymore updates on this? I like the pvc extension you made but you could have saved some time by cutting out the rear of the bucket and using the nut and bolt mouning method like you would with the FXR. The pros are you have endless adjustability if something isn't perfect with alignment and you could recess the projector all the way back until you run out of room behind it. The only con is you have to seal the rear up but they make plenty of fittings to do so. Either way great work and looking forward to the output shots! Remember 25' or more from a wall to check alignment

 

[whitelightning99]

nice we all want to see a vid of them once your done