Kbeanz 4th Gen OEM+ Projector Retrofit Build

[Kbeanz3330]

I finally reached my 15 post minimum so here we are with the short and sweet journey of my headlight build.

Parts List:
Morimoto D2S 5.0
Morimoto xb4500k D2s bulbs
Matsushita Gen. 3 Ballasts & Igniters
TRS Relay Harness
Profile Hi-Lens V1


2007 4Runner Limited 92k miles, this car was given to me by the in-laws. All stock, unmolested, original owner, mom driven, and some nice sun faded halogen headlights.

I thought about sourcing a set of lens's just to swap, but ended up buying a new set of headlights off amazon for $150. This allowed me not to have the vehicle down and take my time building the new lights in the basement.

After disassembly I was able to take measurements of all the factory mounting points. Made this adapter bracket and 3D printed it.

Projector sitting in my bracket nicely.

Profile Hi-Lens sitting in the highbeam bucket. I thought about doing a true quad projector retrofit but aiming is too stressful and it would have driven my OCD crazy.

Projector and led high beams mounted. In the first couple pictures you can see that I opted to go with the FGL on the projector. For those of you that don't know, Foreground limiters function by blocking a lot of the light that would normally go right on the ground in front of the car. Foreground light gives the appearance of brighter headlights but it is just a placebo effect, when you drive at night you look at the road ahead of you not directly in front of your bumper. In this case more light/lumens are sent down the road rather that right in front of your car.

Water-proofing the ballasts since these will be mounted on the underside of the headlight. Normally I would try and fit them inside but there just wasn't enough room.

 

[Kbeanz3330]

Ballasts mounted underneath and buttoned up with dust boots.

Testing feat. a beautiful cutoff

Complete and re-assembly.

Mounted on the truck: before & after
I love the subtle look of the blue coated lens on the D2S 5.0

I still need to do some beam adjustment and get some night time output shots. Hope you guys enjoyed, let me know what you think!

- Kbeanz

 

[blkexp98]

Looking good. I think you were smart to stay with led on the highs. I'm no expert but I think HID doesn't like to be turned on and off quick so led is better for that application. Could you go into your procedure for aiming the headlights?

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[montijo505]

Turned out really clean!


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[riceandpho]

very nice, hope you don't run out of low beam adjustment, when our rigs are lifted, the projectors tend to hit the shroud on the final adjustment, I'm pretty close with my s2000 projectors. if you can, grind out some parts of the shroud to make more clearance.

 

[Kbeanz3330]

very nice, hope you don't run out of low beam adjustment, when our rigs are lifted, the projectors tend to hit the shroud on the final adjustment, I'm pretty close with my s2000 projectors. if you can, grind out some parts of the shroud to make more clearance.

It's funny you say that because thats exactly what happened to me, I have to take the lights back apart and mount the projector on the other side of my bracket to buy a couple mm's of clearance.

 

[Neosapian]

Nice work! Thanks for sharing these images!

 

[Bogrun]

Awesome project and write-up!

Fog lights next? :thumb3:

 

[originalg00kster]

It's funny you say that because thats exactly what happened to me, I have to take the lights back apart and mount the projector on the other side of my bracket to buy a couple mm's of clearance.

bro me toooo haha. :doh: If I open it up again might upgrade my projectors.

also op would you sell those brackets by chance?

 

[riceandpho]

bro me toooo haha. :doh: If I open it up again might upgrade my projectors.

also op would you sell those brackets by chance?

i have done retro with the older style bracket for the d2s 2.0 projector.
its good for what it is, they have the newer style brackets for newer projectors.
these are a very good option for folks that need a quick job without all the extra work.

this light hobby has gotten me using only oem projectors and not using the aftermarket projector. why im more old school, tuned oem projectors are pretty cool when you have experience the performance of those. started with the md2s 2.0 , then moved to a rx330, then to current s2000 on my truck and a rx350 on my lady's camry. they are good at what they are. ones better than the other.
03-09 4Runner D2S 5.0-G5-R Brackets – Lightwerkz Global Inc

 

[riceandpho]

It's funny you say that because thats exactly what happened to me, I have to take the lights back apart and mount the projector on the other side of my bracket to buy a couple mm's of clearance.

I would try that and also if you can, slowly grind the back of the shroud. might need to enlarge the circle. practice on a used set of lights first.

 

[Kbeanz3330]

Awesome project and write-up!

Fog lights next? :thumb3:

Yup, plan on 3d printing some brackets for fogs. Thinking of making an adapter for the morimoto fog lights to drop into our 4th gens.

 

[Kbeanz3330]

bro me toooo haha. :doh: If I open it up again might upgrade my projectors.

also op would you sell those brackets by chance?

Yeah I would sell them if people were interested.

 

[originalg00kster]

i have done retro with the older style bracket for the d2s 2.0 projector.
its good for what it is, they have the newer style brackets for newer projectors.
these are a very good option for folks that need a quick job without all the extra work.

this light hobby has gotten me using only oem projectors and not using the aftermarket projector. why im more old school, tuned oem projectors are pretty cool when you have experience the performance of those. started with the md2s 2.0 , then moved to a rx330, then to current s2000 on my truck and a rx350 on my lady's camry. they are good at what they are. ones better than the other.
03-09 4Runner D2S 5.0-G5-R Brackets – Lightwerkz Global Inc

yeah thank you. i actually am using this bracket right on for d2s 4.0.

 

[AlpinUltra]

Nicely done, sir. They look great on the truck, great use of a 3D printed part!

 

[Maurick]

Hey! Are you willing to print another set of brackets and sell it?

 

[Kryptoroxx]

I finally reached my 15 post minimum so here we are with the short and sweet journey of my headlight build.



Parts List:

Morimoto D2S 5.0

Morimoto xb4500k D2s bulbs

Matsushita Gen. 3 Ballasts & Igniters

TRS Relay Harness

Profile Hi-Lens V1





2007 4Runner Limited 92k miles, this car was given to me by the in-laws. All stock, unmolested, original owner, mom driven, and some nice sun faded halogen headlights.

I thought about sourcing a set of lens's just to swap, but ended up buying a new set of headlights off amazon for $150. This allowed me not to have the vehicle down and take my time building the new lights in the basement.

After disassembly I was able to take measurements of all the factory mounting points. Made this adapter bracket and 3D printed it.

Projector sitting in my bracket nicely.

Profile Hi-Lens sitting in the highbeam bucket. I thought about doing a true quad projector retrofit but aiming is too stressful and it would have driven my OCD crazy.

Projector and led high beams mounted. In the first couple pictures you can see that I opted to go with the FGL on the projector. For those of you that don't know, Foreground limiters function by blocking a lot of the light that would normally go right on the ground in front of the car. Foreground light gives the appearance of brighter headlights but it is just a placebo effect, when you drive at night you look at the road ahead of you not directly in front of your bumper. In this case more light/lumens are sent down the road rather that right in front of your car.

Water-proofing the ballasts since these will be mounted on the underside of the headlight. Normally I would try and fit them inside but there just wasn't enough room.

This has been an absolute pita to get them to seal.

I'm going to see if I can't make something like this. Where did you get the rubber pieces? I used the stocks and they fit reasonably well on the rx350 projectors in the back. Not so much for the d2s 5.0 projectors though.

Very very clean sir. Well done! I made my brackets out of metal and I won't go into how much trouble that was.

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[twbarrett]

I am embarking on a similar retrofit for my 09, using the Morimoto M LED 2.0 projectors. I have a similar hurdle to jump with custom brackets and a little trimming, but one thing that I was expecting seems to be missing from this write-up: trimming the cosmetic shrouds.

The D2S 5.0 has a 3" lens (so does my M LED 2.0) but our factory projectors have 2.5. Is it true that there is enough 'extra space' on the inside of the factory shroud that no trimming was required? That would be fantastic!! I did some test-fitting (holding the parts together by hand) and it looked like it was possible, but it would still be a nice surprise.

EDIT: Also, I'm curious, what sort of plastic did you use to print, and how has it held up inside of your headlight housing? I was planning on using a 3D printer to prototype and then send it out to a metalshop for lasering, but if the plastic holds up OK it could save some time and money.

 

[Tyla_T4R]

This looks so good.

I want to do this so badly since I cannot even come close to affording bxbuilts or teq (which I heard have QC issues).

Is it possible for you to share the 3d file so we can print it ourselves?

 

[twbarrett]

I'll share my file when I'm done prototyping, but it will be specific to the projector that I have chosen (M LED 2.0).

I am hoping OP will come back to answer my question about 2.5 vs 3.0 lenses soon, but if he doesn't, I guess I'll find out for myself

(Farming up to 15 posts so I can post pics of what I have)