Author Topic: How to Retrofit projector into headlights. (del sol)  (Read 9970 times)

Offline B00M3R

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How to Retrofit projector into headlights. (del sol)
« on: February 24, 2010, 07:18:05 PM »
I wrote this a year ago when I finished my retrofit. Some of this has changed but the info is still good. Feel free to post up questions.




I was requested to post up a how too on retrofitting HID headlights so here it is.

This was my first retro, I read a lot and decided on OEM parts because of reliability.

Decided on going with TL projectors. I ended up getting them separately off eBay for $55 and $75. They regularly go for $200 to $250 for a pair.


Next went with Matsushita 3rd gen ballasts($170) with Philips 85122+ D2S bulbs (4300K) ($50).


first time I used my 2+year old ebay headlight and found that it was just too scratched up even after a good sanding and cleaning.
here is the first one, you can see all the cracks and scratches that made me decide on new ones.



So I ordered a new set of headlights in the Black color. ran me $120.  Here is a pic of the untouched headlight.


I then had to pull the headlight apart, it seems the new black ones don't use the same glue that heats up and becomes soft, the new ones use something more like JB weld. so I had to heat in the Oven for longer to make the plastic soft enough to pull away from the hard glue.


Then had to just pry things apart and was a little harder then the soft glue. Next I had to pull out the refection bowl and original bulb. In this case they popped right out. 
Next part was to make room in the bottom of the housings for the solenoid. I used a heat gun and melted the plastic.


Then I used pastic repair kit to fill in the holes and make it sealed again.


Then I needed to place the projectors into the housing and drill holes to hold them in place. also at this time I installed  ZKW-R Clear Lenses.



you can see the difference between the orginal lenses and clear ones here.
Original lenses


I used two Staleness steal bolts in the bottom two holes and made a metal brace that connected to the original adjustment screw.
I then installed Gatling gun shrouds to hide the projectors and give it a cleaner look. 
Here are the clear lenses.


Then I reassembled them sealing them back up.




Next comes the fun of installing them back into the car and aiming them. It's a little hard to find a good spot for the Ballasts close to the headlights.



Here is the money shot for HID retros's. the Cutoff.


any questions let me know.

Offline Eg2alex

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Re: How to Retrofit projector into headlights. (del sol)
« Reply #1 on: February 24, 2010, 07:31:27 PM »
How much u charge? Lol well  would u want to do this if I paid for parts and labor?

If you lean towards the hellgay fucked up offset bs, first mod should be a fs sign not bargain basement coilovers
86 2.0 si prelude-sold
94 cbr 600 RR-sold
91 crx hf-totalled
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90 civic dx hatch-sold AGAIN
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98 civic sedan lx-shared daily
91 crx si-long term project to one day even start..

Offline Ferris

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Re: How to Retrofit projector into headlights. (del sol)
« Reply #2 on: February 24, 2010, 08:12:22 PM »
My only question is how different are my projector lenses in my Teg that came stock vs OEM HID projector lenses. I know that there is a huge difference in the clean ness of light and cut off pattern, my question is why. Could I just get a different lens so I wouldn't need to do a full retrofit to get as clean of a look.

Great work here though Boomer.
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Offline iden32

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Re: How to Retrofit projector into headlights. (del sol)
« Reply #3 on: February 24, 2010, 09:17:35 PM »
yea one question wanna do a subie :D lol
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Offline B00M3R

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Re: How to Retrofit projector into headlights. (del sol)
« Reply #4 on: February 24, 2010, 09:26:14 PM »
How much u charge? Lol well  would u want to do this if I paid for parts and labor?

well in this version I didn't add up all the parts cost, but overall it cost me about $600 to make mine, then about 10 hours of work.
I studied how to make and what parts for about 2 years before I decided to try it.

My only question is how different are my projector lenses in my Teg that came stock vs OEM HID projector lenses. I know that there is a huge difference in the clean ness of light and cut off pattern, my question is why. Could I just get a different lens so I wouldn't need to do a full retrofit to get as clean of a look.

Great work here though Boomer.

I think you could find out the size of the projector lens, and replace it with a better one would make a difference. also you can do mods to the cut off to make it cleaner also. 

yea one question wanna do a subie :D lol

I wasn't meaning to get work out of posting a how too, but i am not against it ether. but as you can see its not cheep doing it OEM style.

Offline iden32

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Re: How to Retrofit projector into headlights. (del sol)
« Reply #5 on: February 24, 2010, 09:30:09 PM »
i am very interested in getting some for the subie :) the current cut off sucks a$$!!! lmk if u r down...
::02 Subaru wrx::

Offline B00M3R

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Re: How to Retrofit projector into headlights. (del sol)
« Reply #6 on: February 24, 2010, 10:04:08 PM »
i am very interested in getting some for the subie :) the current cut off sucks a$$!!! lmk if u r down...
got pics of the headlight you are looking to use?
also any idea what projector you want to use?

Offline iden32

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Re: How to Retrofit projector into headlights. (del sol)
« Reply #7 on: February 25, 2010, 09:33:05 AM »
Right now I am sportin the 02 bugeye I will pm u pix when I get home... And not really sure on the lenses
::02 Subaru wrx::

Offline Travis?

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Re: How to Retrofit projector into headlights. (del sol)
« Reply #8 on: February 25, 2010, 09:35:50 AM »
i wanna retro fit these in my teg

but they are pricey :P

Offline peteyparker

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Re: How to Retrofit projector into headlights. (del sol)
« Reply #9 on: February 25, 2010, 09:41:56 AM »
Awesome write up BOOM3R!!!  Once I get all the parts I need ill let you know how mine turn out!

Offline S.P.Audio

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Re: How to Retrofit projector into headlights. (del sol)
« Reply #10 on: February 25, 2010, 05:02:53 PM »
I say Sticky this.. it's about the same idea as far as how to do this in various makes and models. but this gives you a general idea on what to do..

nice a+++ write up!

Offline WuddaWaste

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Re: How to Retrofit projector into headlights. (del sol)
« Reply #11 on: February 26, 2010, 04:31:44 PM »
Agreed on the sticky.  Super agreed on the amazing write-up.   Thanks for taking the time, B00M3R!
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Offline Ninja

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Re: How to Retrofit projector into headlights. (del sol)
« Reply #12 on: February 26, 2010, 05:26:57 PM »
Didn't you use Bi-xenon bulbs for hi/lo?

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Offline B00M3R

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Re: How to Retrofit projector into headlights. (del sol)
« Reply #13 on: February 26, 2010, 06:14:51 PM »
Didn't you use Bi-xenon bulbs for hi/lo?

I did, and a wire harness that converts the high low from my column. works great.

Offline Walterpoova

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Re: How to Retrofit projector into headlights. (del sol)
« Reply #14 on: September 12, 2019, 03:32:59 PM »
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