Projector mod, different from the rest...

[1996BLKBauer]

Well winter is fianlly here, and I can no longer do projects on my Explorer outside, so I just bring them inside, the project for the next few weeks is a projector Retrofit on my '96 Eddie Bauer. Unlike most of the Retrofits, which use the Morimoto Mini projector housings, I am going to use something larger, only because I got them for free from work.

I will be using Ebay, blacked out headlights, with a clear cover. For the projector I will be using a projector assembly from a 2007-2013? GMC Acadia. The stickers on the projectors say Valeo, not sure on that company, but if they are good enough for factory GM stuff, I can trust it in my Ex.

These projectors are Bi-Xenon, so I will have to wire, both low beams, and high, with the servo. I have a pretty good idea on how to wire them, I just have to acquire so 9007 jumper harnesses, and find some old relays I got laying around, and spend some time wiring. I was able to get 6 head lamp assembly's, so that's 6 projectors, 6 bulbs, 6 ballasts, 6 wiring harnesses, basically 6 of everything I will need to do this project!!! I got them from work due to a recall pertaining to the filament type Daytime running lights, so the HID system still works great, once Parts kept them for a specified amount of time, they throw them out, and I take them out, and cut them up.

Time for pictures!!!
I only baked the lights apart, and hauled the box of projectors in so they can warm up, I did take apart one assembly to get just the projector housing out for mockup.

The Headlights I am modding, just Ebays ones, this is after I got them apart.

My box of projectors, not all of them, a few are in the garage still.

The assembly as they come out of the housing, the other one is the Day time running lights, that melts due to high heat.

Full harness:

After disassembly...

the reason I got all these, a broken, and melted housing...

The projector itself, multiple angles.

Scoping out the situation, I will need quite a bit of housing modification for this, but I'm not scared.

So far this is the progress I have, hoping to have one mocked up tomorrow, but we'll see. Let me know what you think, these are much larger then the Morimoto ones, and I believe the factory bulbs are in the range of 6k, so its basically perfect for what I want.

 

[Reverend Greg]

Subbed! This is on a short list for me after the beginning of the year.
Greg

 

[1997XLTRollover]

Those look expensive haha. Looks like it should be a cool project; can't wait to see the end result.

 

[97exploder19]

Alot of work vs a Mini H1 but theyre free so you cant beat that.

 

[1996BLKBauer]

Alot of work vs a Mini H1 but theyre free so you cant beat that.

They for sure are, but I can get any bulbs, and ballasts from work at Cost, so even if I need to replace anything it still will be really cheap.

 

[1996BLKBauer]

So i ended up being really lazy today, so all I did was buy the harness for the headlights. This so I can just plug the HID harness in and not cut up my wiring.

 

[96firephoenix]

how much do you want for a pair of those projectors? I'm assuming that since you're still able to use them for your swap, that they are in mostly working order, just not able to use on GM cars with the break?

 

[1996BLKBauer]

how much do you want for a pair of those projectors? I'm assuming that since you're still able to use them for your swap, that they are in mostly working order, just not able to use on GM cars with the break?

Not really willing to sell them, only because they are used and I would feel bad if they came to your house broken. I have noway of knowing how long they would work or anything like that.

 

[1996BLKBauer]

Sorry guys, I didn't forget to post, I have been busy with the Holidays, and with my purchase of a new bench for projects. I had the project of putting some thick stainless steel on it which was harder then it seems. Today even though I didn't get too much time to work on it, I was still able to get some things done.

Here we go, Picture time.

First off this is my new project bench, go tit for $30, and slapped some Stainless Steel on it that I had laying around.

Next I cut the back out so that the lamp could fit through the back, this is the first cut, I had to do some massaging later.

Now I sort of got in a groove, so I forgot to take as many pictures as I would like to, but the next part I traced where I though the lamp was going to stick out, then once again worked it until I sit in nicely. The next pictures show the final position of the lamp, with it on of course

So that's it for now I still have to make some finishing rings for it, and mount the lamps, so there is still a lot of work left, but I have to make dinner, so it must wait, on the plus side I already went to Home Depot and grabbed the rest of the supplies.

 

[vroomzoomboom]

not to be a buzz kill, but i think i see a flaw in the way you mounted it. hopefully i am wrong, but is there going to be enough room for your turn signal lens the way you have it? most guys (me included) i have seen have cut the bottom open for room for a retro fit. also there is less chance of water getting in and staying in if you develop a leak over time.

 

[1996BLKBauer]

not to be a buzz kill, but i think i see a flaw in the way you mounted it. hopefully i am wrong, but is there going to be enough room for your turn signal lens the way you have it? most guys (me included) i have seen have cut the bottom open for room for a retro fit. also there is less chance of water getting in and staying in if you develop a leak over time.

It will be tight, but it should fit, It cant really go lower due to how the projector its self is designed. Otherwise I might run out of adjustment for aiming up and down, as it sits now it is basically level in the housing.

 

[1996BLKBauer]

Well finally got to work on them again, for a little bit at least then the heater ran out of fuel...


I did address the issue that [MENTION=61294]vroomzoomboom[/MENTION] brought up. I took a look at the projector housing and found it is not only folded over, it is also riveted on so the top most half got chopped off.

As you can see by this picture there is a ton more room now.

I will most likely follow the foot steps of [MENTION=67319]mcpherson[/MENTION] and make a cover out of some sheet metal, and seal it with some good sealant and metal tape.

Next I made a cover for the bulb to protect it from being knocked about, not sure how I am going to water proof it yet, but I'll figure out a way.

Lastly I made the finish ring out a PVC reducer piece I found at the Home Depot. on the right is the original piece, and on the left is the finished product.

I'll still have to modify it to fit the housing, but the fitment around the projector its self it really good, took me like 40 minutes with sand paper, and a Dremel to make it perfect.

That's it for now, I have to go to work and move my tool box to a new stall, and hopefully on the way home I can grab more fuel for my heater.

I also found a way to mount the projectors, but I will need some more parts to finalize it all up, so give me some time on that. I am really getting excited, they are turning out great.