retrofitting projectors into stock headlights
Joined: Jan 2009
Posts: 533
Likes: 0
From: Orange County, California
Update!!!!
Alright guys after countless hours over the weekend and conquering many different obstacles I have finished this retrofit project. I would give this project a difficulty of 9/10. It could differ between people but it wasn't easy.
Pics will be up soon
Alright guys after countless hours over the weekend and conquering many different obstacles I have finished this retrofit project. I would give this project a difficulty of 9/10. It could differ between people but it wasn't easy.
Pics will be up soon
Joined: Jan 2009
Posts: 533
Likes: 0
From: Orange County, California
OKay sorry guys for not posting pics sooner, my internet was down. Anyways here a few pics ( don't worry ill take many more )



... I have tested the adjustments on the projectors to make sure they are level and properly aligned. I have not completed the wiring for both projectors as i need to run some negative and positive wires to the battery, now i went to my local hardware store and bought some negative and positive wires to run down to my battery but it seems a bit much, i know there is an easier way like splicing into a wire near my headlights or something but if it comes down to it i guess ill have to run each wire to the battery. The wires have a circular terminal looking thing at the end of the wires but the problem is they are about 12 inches long so obivously wont reach the battery, any suggestions/ help would be great..



... I have tested the adjustments on the projectors to make sure they are level and properly aligned. I have not completed the wiring for both projectors as i need to run some negative and positive wires to the battery, now i went to my local hardware store and bought some negative and positive wires to run down to my battery but it seems a bit much, i know there is an easier way like splicing into a wire near my headlights or something but if it comes down to it i guess ill have to run each wire to the battery. The wires have a circular terminal looking thing at the end of the wires but the problem is they are about 12 inches long so obivously wont reach the battery, any suggestions/ help would be great..
Joined: Jan 2009
Posts: 533
Likes: 0
From: Orange County, California
Haha I really don't feel like doing another pair. Too
time consuming and fidgeting for my liking.
They have wonderful output and nightshots
Will be up tomorrow
Joined: Jan 2009
Posts: 533
Likes: 0
From: Orange County, California
Hmm flip the harness as in switch the harness from left to right or just flip the plugs?
Well it could be the way I took the pictures but they sit pretty far back in the housing. I had to dremel the sh*t out of the housing for hours and hours and make sure both headlights matched and fit evenly. Theoritcally you could put them further in but there is really NO room in The back of the headlight, it would touch the rangers frame.
from front to back, how long are the projector casings ?
Joined: Jan 2009
Posts: 533
Likes: 0
From: Orange County, California
I exactly know what you mean. I'll take some pics
I never actually measured the projector from lens to the end but I would guestimate 4 inches give or take. There's not much room to play around with back there but I'm sure I could probably squeeze them back a tiny bit but the problem is the hole I dremeled is almost as wide as the projector itself and the screw holes wouldn't reach the sides, the shape of the projector is a strange oval shape so yah. Really hard to explain but i will take pics for you to see
Exactly, the plugs are the same. Guess they do that to save money
Joined: Jan 2009
Posts: 533
Likes: 0
From: Orange County, California
Sorry everyone for not updating this thread sooner but i have ran into some little flaws so, i have decided to take apart my headlights once again and fix them.

here's the down low, in the pic shown above you can see how the light is back reflecting into the housing and looks ghetto. One reason being the shroud is NOT on all the way, i know i know dumb mistake. You can see in the picture how the shroud is not flush with the projector lens. Its actually an easy fix because all i had to do was turn the shroud to match up with the notches and basically push it into place.
Luckily the silicone i decided to use was EXTREMELY easy to take off, i took an exacto knife and cut it open within 2 minutes. Compared to the Taiwan permanent sealant the headlights come stock with, which took hours to take off.
The light output from these projectors is absolutely amazing, i did try them out and got them aligned pretty well. The cut off line is great and the light has a very wide spread. Look forward to update and pics as i finish off this project
EDIT:
I was thinking of cutting up more of the housing to get the projector as far back as i can, problem being the weird shape. The more i cut the less area i have to mount the projector itself. I don't think its really that big of a deal but if anyone can think of a way i can mount these darn things without having to screw into the housing that would be wonderful. I tested out the silicone strength by smuthering the projector in it and pushing it into housing. It held up better than i thought and wasn't jiggling around at all. I still don't feel confident in using just silicone to hold it in, any other suggestions besides screws ? :)

here's the down low, in the pic shown above you can see how the light is back reflecting into the housing and looks ghetto. One reason being the shroud is NOT on all the way, i know i know dumb mistake. You can see in the picture how the shroud is not flush with the projector lens. Its actually an easy fix because all i had to do was turn the shroud to match up with the notches and basically push it into place.
Luckily the silicone i decided to use was EXTREMELY easy to take off, i took an exacto knife and cut it open within 2 minutes. Compared to the Taiwan permanent sealant the headlights come stock with, which took hours to take off.
The light output from these projectors is absolutely amazing, i did try them out and got them aligned pretty well. The cut off line is great and the light has a very wide spread. Look forward to update and pics as i finish off this project

EDIT:
I was thinking of cutting up more of the housing to get the projector as far back as i can, problem being the weird shape. The more i cut the less area i have to mount the projector itself. I don't think its really that big of a deal but if anyone can think of a way i can mount these darn things without having to screw into the housing that would be wonderful. I tested out the silicone strength by smuthering the projector in it and pushing it into housing. It held up better than i thought and wasn't jiggling around at all. I still don't feel confident in using just silicone to hold it in, any other suggestions besides screws ? :)
Last edited by andddrew says; Jul 29, 2010 at 01:38 AM.
When I did mine on my matrix I used JB weld and screws. I used the screws to get the projectors lined up properly ( rotation, angle , etc..) then when i was happy. I put JB weld over the screws and where I had gaps for strength.
A lot of people use just jb weld too. The best part is IMO you can let it harden and then drill into it if you have to.
3 years and they never moved.
Your headlights look great, Almost makes me want to do a set for mine.
A lot of people use just jb weld too. The best part is IMO you can let it harden and then drill into it if you have to.
3 years and they never moved.
Your headlights look great, Almost makes me want to do a set for mine.
Joined: Jan 2009
Posts: 533
Likes: 0
From: Orange County, California
When I did mine on my matrix I used JB weld and screws. I used the screws to get the projectors lined up properly ( rotation, angle , etc..) then when i was happy. I put JB weld over the screws and where I had gaps for strength.
A lot of people use just jb weld too. The best part is IMO you can let it harden and then drill into it if you have to.
3 years and they never moved.
Your headlights look great, Almost makes me want to do a set for mine.
A lot of people use just jb weld too. The best part is IMO you can let it harden and then drill into it if you have to.
3 years and they never moved.
Your headlights look great, Almost makes me want to do a set for mine.
That's perfect! I actually have some JB weld in my garage, can't believe i didn't think of that. I'll use the JB to let the projetors dry straight then screw them in with some pressure.
and either use nylon locking nuts or a dab of jb on the nuts when you're done.
they won't move.






