domct203
Pilots The Beast
- Joined
- October 11, 2017
- Messages
- 581
- Reaction score
- 169
- City, State
- CT
- Year, Model & Trim Level
- 2002 Explorer XLS
Over this past long weekend I converted my stock headlights to HID projectors with halo lights and ‘demon eye’ LEDs.
Here is the headlight housing, retrofit projector & shroud.
I started by removing the headlights from the truck & removing the bulbs and metal clips that secure the lens. Then I heated the headlight housing in a 220F oven for 8 minutes. This loosened the seal and made it possible to remove the clear lens.
Once I had the headlight housing open and I removed the bulb cover, and all the old dried up sealant, I test fit the projectors and realized that I had the make a bit of clearance on the old bulb cover mount. Using a dremel with a small sanding drum I easily sanded down the needed clearance. I passed the sanding drum in from the back side.
Once I was satisfied with the fit of the projector I began assembling the demon eye and halo LED. To mount the blue demon eye, I removed the led from the included plastic mount, then drilled a small hole in the plastic lens housing and used epoxy and a screw to attach the LED.
This did require me to make a bit of clearance on the inside of the shroud, sorry but no pics of that.
Next I mounted the halo lights to the front of the shroud using .021” SS safety wire. If you look closely in this pic of the inside of the shroud you can see the safety wire tucked up under the halos. You can also see that I drilled a hole through the shroud for the halo wires. [edit] In this pic you can see the clearance I made for where I mounted the blue demon eye LED, it's opposite where the halo wires come through the shroud [/edit] I oriented the wire on the bottom of the shroud, and painted the wires silver. You can hardly see it, and do not notice in the finished product unless I point it out.
Here is the headlight housing, retrofit projector & shroud.
I started by removing the headlights from the truck & removing the bulbs and metal clips that secure the lens. Then I heated the headlight housing in a 220F oven for 8 minutes. This loosened the seal and made it possible to remove the clear lens.
Once I had the headlight housing open and I removed the bulb cover, and all the old dried up sealant, I test fit the projectors and realized that I had the make a bit of clearance on the old bulb cover mount. Using a dremel with a small sanding drum I easily sanded down the needed clearance. I passed the sanding drum in from the back side.
Once I was satisfied with the fit of the projector I began assembling the demon eye and halo LED. To mount the blue demon eye, I removed the led from the included plastic mount, then drilled a small hole in the plastic lens housing and used epoxy and a screw to attach the LED.
This did require me to make a bit of clearance on the inside of the shroud, sorry but no pics of that.
Next I mounted the halo lights to the front of the shroud using .021” SS safety wire. If you look closely in this pic of the inside of the shroud you can see the safety wire tucked up under the halos. You can also see that I drilled a hole through the shroud for the halo wires. [edit] In this pic you can see the clearance I made for where I mounted the blue demon eye LED, it's opposite where the halo wires come through the shroud [/edit] I oriented the wire on the bottom of the shroud, and painted the wires silver. You can hardly see it, and do not notice in the finished product unless I point it out.
