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P51's HID Headlight (Projector) and Fog Conversion (PICS)

Here is my writeup for doing a Bi-Xenon HID Projector Retrofit for 96-01 Explorers, and HID Fog Light conversion for 99-01 Explorers.

Parts:

Clear Housings
E46 Bi-Xenon Projectors
3" Projector Shrouds
D2S HID Kit @ 5000k (Now 4300k)
H1 HID Kit @ 5000k (Now 4300k)
High Beam Controllers
3 Relays (30amp)
2 Diodes (3amp)
Fuse block (or inline)

To start you need to open up the headlight housings
First remove all the mounts from the housing
IMG_0042.jpg


Then put the light on a baking tray with tinfoil in the oven and preheat the oven to 400 degrees. put the headlight in the oven and wait about 5-10 min, CONSTANTLY MONITOR IT and make sure it doesn't get soft.
IMG_0045.jpg


Now its time to modify the housing to fit the protector
IMG_0050.jpg


Cut out all the plastic from the inside of the circle. I found that the barrel sander Dremel attachment worked the best.
IMG_0051.jpg


Now cut along the bottom to make room for the projector solenoid
IMG_0054.jpg


The Projectors (Note: They are upside down)
IMG_0048-1.jpg


Fit the projector into the housing
IMG_0056.jpg

IMG_0057-1.jpg

IMG_0058.jpg


Now onto the High Beams, I didn't have the actual wires, so I desoldered the connection off the board and soldered on my own leads.
IMG_0059.jpg


Mark and Drill the holes to mount the Projectors
IMG_0062.jpg


I used some of my old LEGOS as spacers, and used Plexiglase to seal the light back up. (NOTE: Cut the excess screw off it will interfere with installation later.
IMG_0089-1.jpg


Done (No shrouds at the moment)
IMG_0068.jpg


Now This isnt necessary but its a nice touch. I put 3 LEDs in to come on when the mirror lights come on. When you click unlock on the key fob these come on and do give off quite a bit of light. Cover with silicone.
IMG_0113.jpg


These are the LEDs not the HIDs
IMG_0116.jpg


Pax side Ballast locations
IMG_0084copy.jpg


Driver side Ballast locations
IMG_0085copy.jpg


HIDs vs Friends Subaruaruaru Stock Halogen
Lights-1.jpg


Fogs

The only major modification needed to do the fog conversion is to modify the bulb socket. Cut out the center of the ring and thats all. Sorry about the piss poor pic but all I had was my cell phone camera.
0229081730a.jpg


Seal up the socket with some silicone and splice into the pigtail wire that goes from the chassis to the bulb, and connect that with the power in lead of the HID ballast.
IMG_0088dcopy.jpg


Close up of Pax side Fog Ballast
IMG_0083.jpg


Done, Getting ready to go Skiing behind the Explorer :)
IMG_0075s.jpg

NOTE: The all Ford fleet.:thumbsup:

Wiringdaigram.jpg


Good Luck

EDIT: Daytime Pictures and Pics with shrouds installed on post 27
EDIT: Cutoff Pictures added on post 109
 



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slickemhoundd

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how much did everything run you?
 






MustangP51

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2009 Limited V8
Headlight Housings: $148.99 eBay
Projectors: $177.39 eBay
D2S HID Kit: $109.99 shopxenon.com
H1 HID Kit: $109.99 shopxenon.com
High Beam Controllers: $18.00 random guy (see post 4)
Projector Shrouds: $99.00 eBay
Fuse Block: $12.99 Advance Auto
Wiring/Diodes/Relays ~$30.00

Total: $705.36

Never really wanted to add those numbers up before, but I still think having the HIDs are well worth it.
 






sporttractuner

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Have any of you HID guys had to deal with the DRL(Daytime Running Lights). My HID's are great, but since in canada, we have daytime running lights. my HID flicker when not on. so I have to manually turn them on during the day.
I know the DRL's are just the high beams running at a lower voltage, but I don't have the manual, and I can't find the fuse to dissable them. Also. my HID's only only have a standard bulb for high beams. What brand are you running to have HID high and low?...K, and last question. I've heard of melting the for housing with an HID kit. any feedback on that?

Thanx Guys
 






MustangP51

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Have any of you HID guys had to deal with the DRL(Daytime Running Lights). My HID's are great, but since in canada, we have daytime running lights. my HID flicker when not on. so I have to manually turn them on during the day.
I know the DRL's are just the high beams running at a lower voltage, but I don't have the manual, and I can't find the fuse to dissable them. Also. my HID's only only have a standard bulb for high beams. What brand are you running to have HID high and low?...K, and last question. I've heard of melting the for housing with an HID kit. any feedback on that?

Thanx Guys

I think there is a thread on here somewhere that has a how to on disabling the DRLs.

As far as your question about the high and low beams.
With my setup the high and low beams are controlled by a shutter in the projectors. The HID bulb is a single D2S bulb that runs unaffected by the beam.

The HIDs actually run cooler then standard halogen bulbs so melting the housings is not a concern.
 






MustangP51

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As upon requests here are some daytime pics and closeups with the shrouds installed.

IMG_0146.jpg


IMG_0149.jpg


IMG_0152.jpg


IMG_0154.jpg
 






jayRock

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what values did you use for the diodes? i know it says 3 amps, but what about the voltage, i heard the higher the better.

and are the relays 30 amp 12v and 5 pin? like the regular automotive relays you can find on ebay and other part stores.

Also what gauge wire did you use to solder your own leads onto the board? Looks like 18-22 ga.
 






MustangP51

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what values did you use for the diodes? i know it says 3 amps, but what about the voltage, i heard the higher the better.

and are the relays 30 amp 12v and 5 pin? like the regular automotive relays you can find on ebay and other part stores.

Also what gauge wire did you use to solder your own leads onto the board? Looks like 18-22 ga.

Here is a link to the diodes that I bought.
http://www.radioshack.com/product/i...&cp=2032058.2032230.2032269&parentPage=family

The relays are 30amp 12v and have 4 pins, power in, power out, ground, and switch.

Here is the wire
http://www.radioshack.com/product/i...&cp=2032058.2032227.2032238&parentPage=family
 


















Bmwz389

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Were the bezles (shrouds) custom made before you ordered them? Or did you cut them to fit?
 






jayRock

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i like the results so far, im ordering the projectors soon (e46's with shrouds for $150) I might make a second pair if someone wants one.. im not looking to sell them for an outrageous price either.
 






MustangP51

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Were the bezles (shrouds) custom made before you ordered them? Or did you cut them to fit?

I had to cut the shrouds to fit.
 






patman

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can i see a pic of the three led's that you put in for when the door is open?
 






MustangP51

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can i see a pic of the three led's that you put in for when the door is open?

There is one in the original post. its the 14th picture.
 












MustangP51

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i'm sorry i should've been more clear i would like to see a picture of the three led's when they are on

Sure Ill get a picture as soon as i can
 









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MustangP51

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I just got home this morning, I had left my Canon S2 here, Now I finally get a good picture. Thanks for reminding me though I would have forgotten.
 






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