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Old 11-09-2011, 09:45 AM #1
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Bandit Runner's Projector Headlights

I had mentioned in one of the other threads that I was working on a projector retrofit into my OEM headlights, so I thought I would start my own thread.

I am a complete noob regarding this type of mod, so I had been researching this and reading everyone elses retrofit threads for quite a while. About 6 months ago or so, I saw that someone posted a discount code of 25% off at TheRetroFitSource.com. I figured it was now or never. I emailed Matt at TRS and asked a ton of stupid questions. He was really nice and patient with me and answered all my questions. Then I purchased this kit:Bi-xenon Morimoto Mini Stage III Kit (H1) - Complete Retrofit Kits from The Retrofit Source Inc
Its the Bi-Xenon, Morimoto, Mini Stage III Kit. I got the standard kit options including the 4300K bulbs and gatling gun shrouds.

A few weeks ago, I finally started working on it. But first I ordered a set of aftermarket headlights off ebay to put in my truck temporarily while I worked on my retrofit into my OEM headlights.

The first thing I had to do was remove my headlights. This was not an easy task for me, because my bumper hoop is in the way of allowing the grille to be removed. So, I had to remove my skidplate, to remove my bumper, to remove my grille, to remove the trim piece under the headlight, to finally remove the headlights.

Here's a pic of everything removed (truck looks kind of naked):


Then after figuring out where all the wires go and connect to, I started laying out the harness in the engine compartment. Then I decided to make sure the projectors worked before I went any further, so I installed the bulbs into the projectors and set them in the engine bay and connected everything. I turned on the headlight switch, and BAM...Let there be light! Everything worked on the first try. Yes, success! (I was really proud of myself at this point)


Then I wire-tied the harness in place, and mounted the ballasts and relay in the engine compartment. It was tight, but I found room for everything. My only complaint was that the wire harness could have been a little longer, to allow more options for mounting the components, but I made it work. Then I installed the aftermarket headlights and put the truck back together.

Then I moved into the house for the next big step: opening the OEM headlights. I put them in the oven (wife was not home at the time) for 12 minutes at 250 degrees. I took them out and pryed them apart with a flat blade screw driver. Success:


Then I test fit the projectors into the headlights (sorry, no pic of this). I found that I had to make a few minor changes to the headlights so that the projectors would sit properly into the reflector bowl. There were a couple of "bumps" that located the OEM reflector piece that needed to be removed. So I zinged them off with the dremel. I also had to cut a slot for the hi-beam solenoid wires to come through. Again, the dremel took care of this, no problem.

One of my main reasons for doing this mod was so that I could black out my headlights. So, a few days later, I lightly sanded the chrome inside the headlights to scratch it up. Then I masked them off, and painted them with a few coats of semi-gloss black, high temp, engine paint.


They turned out good. Here's a pic with the masking tape removed:


Last night, I cleaned up the projectors and shrouds, and removed all the fingerprints to get them ready for installation.


That's where I am at currently in the process. I hope to get them installed this coming weekend. Can't wait!

Thanks for looking.
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Old 11-09-2011, 09:52 AM #2
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Nice work so far. Those black housings are gonna look nice on your rig when it's all buttoned up!
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Old 11-09-2011, 10:09 AM #3
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dang dude that looks like a ton of work just for lights. but im sure it'll be worth it for you if you drive it alot.
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Old 11-09-2011, 11:16 AM #4
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I like it, very nice work. I'll be interested in seeing what the black headlights look like. I've been considering doing this myself. Good write up!
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Old 11-09-2011, 11:34 AM #5
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Hi Bandit Runner. Sent you a PM. Cheers!
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Old 11-09-2011, 11:57 AM #6
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man! i so wish i would have painted my headlight housing black when i did mine...
I'm Subscribed. i cant wait to see the results. your gonna love the light output.
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Old 11-09-2011, 02:15 PM #7
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im starting mine today! doing pretty much the exact same setup, just with the d2s and different shrouds
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Old 11-09-2011, 03:31 PM #8
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Looking great so far!

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Old 11-09-2011, 03:49 PM #9
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Can't wait to see the finished product!
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Old 11-09-2011, 08:08 PM #10
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This will be very helpful for me in the future!
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Old 11-10-2011, 08:39 AM #11
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Thanks for all the positive comments everyone.

Quote:
Nice work so far. Those black housings are gonna look nice on your rig when it's all buttoned up!
Yeah, I hope so.

Quote:
dang dude that looks like a ton of work just for lights. but im sure it'll be worth it for you if you drive it alot.
Its not that much work, and I drive it every day.

Quote:
I like it, very nice work. I'll be interested in seeing what the black headlights look like. I've been considering doing this myself. Good write up!
I'm anxious to see the black headlights too.

Quote:
man! i so wish i would have painted my headlight housing black when i did mine...
I'm Subscribed. i cant wait to see the results. your gonna love the light output.
Painting the housings black was one of the things that got me started thinking about the retrofit in the first place.

Quote:
im starting mine today! doing pretty much the exact same setup, just with the d2s and different shrouds
Oh, cool. What shrouds did you get? Be sure to post pics.

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Looking great so far!
Thanks, I hope they turn out as good as I think they will.

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Can't wait to see the finished product!
Me either!

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This will be very helpful for me in the future!
Glad to be of help.

Everything is in place to get these finished up this weekend. (Including the wife being out of the house, so I can use her oven again. Darn kids better not snitch on me though. HaHa)
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Old 11-10-2011, 09:55 AM #12
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Originally Posted by Bandit Runner View Post
Everything is in place to get these finished up this weekend. (Including the wife being out of the house, so I can use her oven again. Darn kids better not snitch on me though. HaHa)
Threaten them . Or Bribe them. Everybody has their price!
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Old 11-13-2011, 10:41 AM #13
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They're Done!

Well, I got up early Saturday morning, and got to work. First, I installed the projectors into the housings.


Then I decided to test them in the truck one more time before sealing them back up. I installed the bulbs, and quickly connected everything. Turned the switch, and everthing worked fine, just like before.


Next, I took them back off the truck, and removed the bulbs again. Then I set the glass lenses onto the housings and put them back in the oven for 13 minutes at 250 degrees. When I took them out, the glue was nice and gooey. I had some thick gloves on, and squeezed the glass and housings back together. Then snapped on the clips that hold the glass to the housings.
Here's what they looked like at that point:

And the backside after reinstalling the bulbs and OEM rubber cover:


Finally, it was time to put everything back together for the last time. Install the headlights, then the trim piece under the headlights, then the grille, then the bumper, and then the skidplate.
Completed:



I really like the way they look. They turned out awsome! Its a pretty basic retrofit, with no fancy LEDs or halos or anything, but I really like it. Later that night, I took a quick trip to the store, and got to try them out. Wow - They really are bright! And the cutoff with the purple color is so cool. (My son really liked the purple.)

I still need to adjust the aim of them. They point downward pretty low. I think it is because of the rake in my lift, having the back of the truck higher than the front. I'll try and do that tonight.
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Old 11-13-2011, 12:30 PM #14
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Looks good, great project. I love the black headlights but I always thought that killed the light output. Did I hear wrong?
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Old 11-13-2011, 12:52 PM #15
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I love it man. I was ify about the black headlights but i think they came out very well and fit your truck good. Nice work.
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