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
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