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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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BrianDye

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Wow I feel dumb, I was crazy for the halo 1-piece projector setups, but they dont even compare to these! I had 2 chances (2 members selling something basically like this) that I passed up :(

If anyones selling a set, let me know and ill buy them!!
 



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Fordy55

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How did you wire the LEDs inside the headlight?
 






MustangP51

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How did you wire the LEDs inside the headlight?

They are wired to a black/blue wire coming from under the dash that powers the interior dome lights.
 






MustangP51

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****** UPDATE ******

Well its been a 2 years since I did this retrofit. To date I have had no issues with this setup. Today one of the fog light failed, after some trouble shooting I found that it was the bulb that went so I order 2 sets of bulbs.

2 H1 @4300k for $15.99
2 D2S @4300k for $15.99

I decided to switch from 5000k down to 4300k, over the last 2 years the bulbs have color shifted to the point they almost look like 6000k. While it does look cool I have definitely noticed that the bluer light is much less effective on wet roads.

I will upload new pictures comparing the 5000k and 4300k when the swap is done.

:chug:
 






GUNITALLREDY

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did you ever get any pics of the swap and if i buy all the parts u wana do mine lol:D
 






Afboy143

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****** UPDATE ******

Well its been a 2 years since I did this retrofit. To date I have had no issues with this setup. Today one of the fog light failed, after some trouble shooting I found that it was the bulb that went so I order 2 sets of bulbs.

2 H1 @4300k for $15.99
2 D2S @4300k for $15.99

I decided to switch from 5000k down to 4300k, over the last 2 years the bulbs have color shifted to the point they almost look like 6000k. While it does look cool I have definitely noticed that the bluer light is much less effective on wet roads.

I will upload new pictures comparing the 5000k and 4300k when the swap is done.

:chug:

Where did you order your bulbs from? I see your fogs were xentec. I had a kit fail within 3 months on my brother's car so I'll never buy their stuff again. I strictly stick to DDM tuning
 












mcpherson

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acchan

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In your opinion, will it have a similar effect as these: Dead Link Removed only cost less?
 






mcpherson

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In your opinion, will it have a similar effect as these: Dead Link Removed only cost less?

Maybe I misunderstood you. Are you referring to using the diamond style headlights with only HID bulbs or retrofitting the diamond style headlights with a Bi-xenon projectors?
 






acchan

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Here's my plan so far. I don't like the look of the spyder projectors http://www.amazon.com/Spyder-Auto-Explorer-Projector-Headlight/dp/B004W4OPCY so I was thinking of upgrading to clear blacked out headlights like these http://www.amazon.com/111039-Explor...TF8&coliid=I1IYTD79Y5JPGA&colid=3LN9TSZ7J23Y8 I like the look of HID lights but a friend of mine put some in his Jeep without projectors and they look terrible. I read that the projector lenses help distribute the light better so I was trying to find a lense with a single projector. So I'm still trying to decide what to do. I can either get the retrofit kit or the lenses like yours. I'm just looking for suggestions on what people think would be better.
 






acchan

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I would like to have single projector lenses but I'm trying to decide if it would be better to retrofit or purchase ones like yours. If I retrofit it then it will be a single projector in reflector style lenses.
 


















jayRock

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are those aftermarket projector headlights on ebay any good? I wish I had an even beam like the acura rl/tsx's do..
 






Steeda04SVT

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Did the early 2000 and 2001 Explorer's come with lights under the mirros or was that a personal mod?
 






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celly

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Steeda04SVT

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I found some on ebay. What size bulb goes in the puddle lamps?
 



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