HID Projector Retrofit - '02 Explorer Sport | Page 2 | Ford Explorer Forums

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HID Projector Retrofit - '02 Explorer Sport

UPDATE: after a few years of use, here's what I've learned:

The CFL halos are ****e. One burned out within a year. I replaced them with these LED halos from SuperBrightLEDs

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These things are fracking BRIGHT! They are also a new product since the date of my original installation, there are more LEDs on it than the amber LED halos which I have facing aft.
I chose the 80mm "cool white" halos. They are slightly larger than the mini H1 projector housings and have stayed in place with a dab of superglue. I also decided to wire them such that they flash with the blinker instead of always being on with the DRL. They are on, then turn off when the amber DRL brightens up for turn signals or hazard flash then cycle through until flashing stops. Here is a short video showing that.

I am still very happy with the original projector retrofit, the only problem has been some corrosion on a pin in the TRS controller unit, causing one headlight not to ignite. This was solved with a bit or dielectric grease on the connector for the controller.

NOTE: I purchased a new flasher relay which accounts for the lower resistance of LED taillights... the flashing is now at a normal pace instead of the "hyper-flash" which normally results from installing LED bulbs in a flashing position. Pull your relay (under the driver's kick panel and find the corresponding flasher unit on SuperBrightLEDs... The new relay was larger and would not allow me to replace the plastic piece which snaps over the relay array... the main kick panel still bolted on fine.
 






I've been researching ideas for a little bit now, I know I want to use the mini h1, Amber led halo (inside shroud) w/ 4300 or 4500 bulbs. I'll use a shroud but not to sure which yet, something to fill in the bowl nicely. I'm debating on some led accents but limited on options with our basic circle designed headlight, I may just use led strips in the corner lens (Amber). I'm going to paint the reflector but not 100 on color (white truck), was thinking white but it may just have to be black.

Thanks for updating the thread

I just installed the new led flasher and yea it is bigger. I didn't want to just toss the cover so did this instead. Used a dremel, I think it looks good/clean
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Anyone interested in making a pair of these for me? I'll buy all the parts? :-)

PM me if interested..

2001 Expo Sport..

My headlights are all pitted and foggy. I'd switch to projectors , etc if someone is willing to make a kit for me.
 






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