Xenon Projector Upgrade.
Want to upgrade to xenon's bulbs or HID's?
Pic 1: You should have the right optics.
Pic 2: Or your car is going to look like this to oncoming traffic.
Pic 3: Xenon projectors tested with an LED Flashlight - No Glare
Skill Level: Intermediate
Parts: Morimoto Mini H1 Projectors
Xenon Depot H1 Bulb & Ballast set
USDM Projector style headlights
two 3"x 4" PVC general purpose drain
Stretch and seal tape
Pic 1: You should have the right optics.
Pic 2: Or your car is going to look like this to oncoming traffic.
Pic 3: Xenon projectors tested with an LED Flashlight - No Glare
Skill Level: Intermediate
Parts: Morimoto Mini H1 Projectors
Xenon Depot H1 Bulb & Ballast set
USDM Projector style headlights
two 3"x 4" PVC general purpose drain
Stretch and seal tape
Remove Headlights
Open hood
Remove grille (4 clips & 3 screws)
Remove headlights (3 Screws)
Remove grille (4 clips & 3 screws)
Remove headlights (3 Screws)
Gather the Materials & Parts
Pic 1:
Two 3" x 4" General purpose PVC Drain
Stretch & Seal tape for waterproofing.
Pic 2:
I chose the drain as the diameter matched the original headlight housing perfectly.
Also, the top of the drain provided a flush mounting surface for the projector housings
Pic 3: Disassemble your headlight housings
Two 3" x 4" General purpose PVC Drain
Stretch & Seal tape for waterproofing.
Pic 2:
I chose the drain as the diameter matched the original headlight housing perfectly.
Also, the top of the drain provided a flush mounting surface for the projector housings
Pic 3: Disassemble your headlight housings
Making the Housing.
Pic 1: The reason for choosing the general purpose drain was:
PVC - can withstand temperature fluctuations
Durable
Waterproof
The top of the drain provided a flush mounting surface for the projector housings
I chose the drain as the diameter matched the original headlight housing perfectly.
Pic 2: Using a table saw cut the drain to height.
(Take off 1mm of material every pass if using a table saw)
You can also use a rotary tool or hand file.
Pic 3: Trim PVC piping to have a step.
This allows the housing to fit within the front of the housing.
Pic 4: A look from inside.
PVC - can withstand temperature fluctuations
Durable
Waterproof
The top of the drain provided a flush mounting surface for the projector housings
I chose the drain as the diameter matched the original headlight housing perfectly.
Pic 2: Using a table saw cut the drain to height.
(Take off 1mm of material every pass if using a table saw)
You can also use a rotary tool or hand file.
Pic 3: Trim PVC piping to have a step.
This allows the housing to fit within the front of the housing.
Pic 4: A look from inside.
Cutting the PVC Drains to Size
Pic 1: After fitting the projector into the new PVC housing
I had to reduce PVC Drain housing height
This reduces the gap between projector and refractor
Pic 2: Took a few quick measurements and figured it out.
Pic 3: New lenses!
Pic 4: Broken tab.
Pic 5: Shaped a piece of aluminum to fit within tab area.
Pic 6: Bent the piece to fit into the broken tab area. (follow up with epoxy)
Pic 7: PVC Drains cut to size
I had to reduce PVC Drain housing height
This reduces the gap between projector and refractor
Pic 2: Took a few quick measurements and figured it out.
Pic 3: New lenses!
Pic 4: Broken tab.
Pic 5: Shaped a piece of aluminum to fit within tab area.
Pic 6: Bent the piece to fit into the broken tab area. (follow up with epoxy)
Pic 7: PVC Drains cut to size
Mounting the Projector
Pic 1: Finally after another trimming, I find the right height.
Pic 2: Cut a circular disk that fits within the drain (to replace the original drain mesh)
Use original mounting points for the drain mesh to mount the circular disk
Drill a 1" hole to fit the projector housing in.
Pic 3 - Projector housing mounted
Pic 4: Click tabs were made to click fit the new housing into the original
Pic 5: The click tabs lock into the inner lip of the original housing
Pic 6: Loaded!
Pic 7: Finish the housing for the other side
Pic 2: Cut a circular disk that fits within the drain (to replace the original drain mesh)
Use original mounting points for the drain mesh to mount the circular disk
Drill a 1" hole to fit the projector housing in.
Pic 3 - Projector housing mounted
Pic 4: Click tabs were made to click fit the new housing into the original
Pic 5: The click tabs lock into the inner lip of the original housing
Pic 6: Loaded!
Pic 7: Finish the housing for the other side
Pic 1: Nice.... no glare.
Pic 2: Quick test indoors.
Pic 3: Done!!
Pic 4: Testing!
Pic 2: Quick test indoors.
Pic 3: Done!!
Pic 4: Testing!