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projector retrofit

9K views 17 replies 14 participants last post by  DustinJ88 
#1 ·
a few have asked me about my headlights that i retrofitted.. all this is copied and pasted from Cfans.. i did this about 2 years ago


i love my HID's but the beam pattern sucks horribly and is blinding to oncoming traffic....

so my plan is to retrofit these (valeo D2S projectors)





into these




i chose chrome because i thought it would flow better than the stock black housings, since the shrouds will be chrome too.. i will be taking pics of the whole process in case anyone else is interested in doing this.. all of my parts are on the way and should be here next week, all i have left to get is a set of shrouds, but i'm not sure what i want to use yet... so far this project has turned out to be pretty expensive, and i havent even started yet :lol:

projectors - 148
new upper and lower headlights - 162
new 10000k D2S bulbs and connectors - 160
shrouds - ??

hopefully it'll all be worth it in the end

next post
well... all the meterials are here except for the upper turn signal lamps (will be here tomorrow)



i'll probably start cutting into them this weekend, i'll be taking pics of the process, so far it seems like it's gonna be an easy project

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well i started on them today, baked the headlights and removed the lens and disassembled the whole housing, it's pretty easy to take apart..

click for a larger view

this is the entire housing disassembled



first thing i did was fab some mounting brackets for the projectors, i used 4" square blank recept covers, took some measurements then started cutting with the dremel





after that i started cutting into the headlight housing




this is how the bracket will mount to the housing, i'll be using JB weld to attach the bracket, it should hold well, i hope :lol:



here you can see how the projector mounts to the bracket, i used nylon spacers to bring the projector forward..





and this is just a test fit of the projector inside the headlight, just to make sure everything fits, and it does.







thats all i've done so far today, i'll have at least 1 headlight complete tomorrow (i hope), i'm gonna make my own shrouds for them, was gonna get a set of A4 shrouds but they are just toooooooo expensive

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ok so the JB weld has set and is holding strong, so i mounted the projector to the housing and test fitted everything, the shroud is just sitting on top and is still not complete yet.. the next task is to install it into the truck and aim/adjust the beam, which i will do later today... this is what it looks like now with the lens just sitting on top



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here's a couple more pics of how the bracket is attached. like i said, i used JB weld to attach it and it's holding up well, i even tried to pull the bracket off, but it wouldnt budge..






i'm working on the other headlight right now, i didn't get a chance to put the other one in the truck, it''s a bit too cold outside, so i'll just end up doing them both at the same time, should make it easier anyways

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that's what i'm doing :wink: i made my own shrouds.

it's not quite finished yet, but this is what it will look like






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fitted the headlight today and aligned the beam.. you can see the huge difference in the stock housing compared to the projector.. notice how sharp the cutoff is.. i still have to attach the shroud and put the headlight back together, i have 1 headlight pretty much complete... it's kinda hard to see the cutoff in these pics since it's still light out, but you get the idea















i should have them both done by the end of the week :D

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well here it is.. still gotta do a bit of fine tuning to get the beam perfectly (or close to) horizontal.. stock housing on the right, projector on the left

outside


inside the cab


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finally got around to putting the headlights back together today, just waitng for the silicone on the upper lights to cure, but the lowers are DONE

click to enlarge














here you can see how bad the high beams are off OOPS.. oh well, i dont really care i'll probably never use them anyways




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here's a few new day pics with the new upper lights installed








end
 
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#15 ·
yeah, retrofitting those wasn't hard at all, if you kinda know what you're doing (i didnt have any idea wtf i was doing honestly :lol:) and have the right tools you shouldn't have any problems.. i think it took me 1 weekend to get both lights completed from start to finish
 
#18 ·
I'm guessing that the angle of the back plate, that was used to mount the projector to the housing, was not mounted to the exact same angle as it came from factory. It most likely tilted forward too much. When tuning the new projector lows back to proper height, the highs were raised too much. Like he said though, with nice bright lows, how often will you need the highs?

Great work man
 
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