Projector Retro....And So It Begins

[triguy74]

After much deliberation and studying online, I've pulled the trigger and purchased a set of TSX/RDX projectors. Rather than buy a full set of '05 headlights to swap out, I bought a single '05 headlight off eBay that had broken tabs. Got it for $15! That way I can try it out on the dummy headlight before I jump into the main pair.

I've done a ton of research on various websites. (including this one) Any specific pointers on doing the mod on a 03-05 4Runners? I'd love to hear 'em! I plan to start next week.

 

[paraordnance]

is your TSX have clear lenses (replicas) on them? They are the only way to go in my opinion. Also get a pair of Phillips bulbs for test firing your projectors. Kit bulbs usually dont give a good results and you will be thinking something wrong with your projectors/cut-off shield etc. That happened to me and I didnt know what to do until switched to Phillips.
Paint part of a shield facing bulb - flat black, this will improve your cut-off, TSX are known for its flares
Do a LOT of testing before each step forward, that really helped me and I avoided major screw-ups
Good luck!

 

[triguy74]

i'm not sure about the clear lens/replica answer. the projectors (and lenses) are from an '07 RDX...and the research i've done says they are the same as the TSX projectors.

They take a D2S bulb. So i was planning on buying a 55W kit from http://www.ddmtuning.com as well as a 35W kit for my fogs.

Thanks for the heads up. I plan to take my time with this mod! I'll take lots of pics along the way.

 

[triguy74]

just got a few of the goodies for the retrofit today from the UPS guy. woo hoo!
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[SimonSez]

Make sure to keep us up to date on your progress and take lots of pictures along the way for a write-up. I'm really interested in doing this kind of thing too. Good luck!

 

[triguy74]

I quick project update. Friday I baked the extra headlight I bought and separated it. That was surprisingly easy.

Today I went to Lowes and bought some 3" bolts, Dremel tool, 2.5" hole saw bit, and a few other goodies.

This took me about 45mins including taking lots of pics. I haven't mounted it or put any bulb in it yet. Just took my time with the saw and dremel. I'm still messing around with it so that I can knock the "real" ones out pretty quickly.

Here's one photo for now...I have <b>A LOT</b> more to come.<br>

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One thing I thought I would ask. It seems like the only piece of the headlight that I actually will modify is the reflector. So if this one goes well, I could just install this reflector in the headlight assembly that's in my car. Then, I can just buy another broken tab headlight (passenger side) on eBay and do the same to it. Right?

There are 4 main pieces to the headlight...the clear cover, outer reflector frame, the actual reflector and the grey body of the headlight.

Thoughts? Seems like a safe(r) way to go just in case something goes wrong.

 

[triguy74]

I got impatient...here are a few more pics. The full write up with come when I'm done. I have just done enough so far to actually mount the projector. They still need more work to adjust and the "permanent" mounting.
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[W211_to_T4R]

Looks really good! Just remember to install the headlight housing onto your truck and aim/adjust the projectors before you reinstall the clear lens. This took me several tries to get it dialed in correctly. I also used the gatling shroud since no other shroud will cover all of the projectors completely.

Another thing I did was on the back of the housing, there are 2 caps that acts as a breather. I removed them and inside is a sponge/filter. Remove the sponge/filter and drill a hole on the cap to help circulate more air into the housing. Re-install the sponge then the re-install the cap. I haven't had any issues with condensation on my headlights.

 

[paraordnance]

Great progress so far! Looks like you going through the same work I did earlier

Taking lights apart is easier than I thought. And after that you can be rolling in couple hours. Good you have a spare headlight to play around. I was working with brand new set and luckly it turned out good. There is couple things you have to be aware. Your rotational adjustment must be bang on, even couple degrees out with sharp cut-off will really show. Some make mounting holes in reflector slightly bigger than bolts to be able to fine tune them once projector in before you all sequre in place with JB weld. Other thing to consider on this one its depth. Not sure which shroud you using but TSX is quite long projector compare to others and on drivers side battery is not far away.

My minigun shroud was almost touching front headlight cover and you only have 1-1.5" to the battery with D2S adapter on. So dont set projector to far.
Use only compressed air (if available) to clean reflector after dremel. I was trying to wash it and its scratches easely.
I suggest use wiring relay harness instead of pluging HID kit directly to factory plug. This way you running from battery.
In couple days you will be enjoing a different world. Specially if you got yourself a 55W ballast. :bigok:

 

[triguy74]

paraordnance, how did you mount the projector? i don't see any bolts coming back from the mounting brackets on the projector. thanks!

 

[paraordnance]

same way you doing. Threaded rod/bolts.

 

[W211_to_T4R]

Triguy, here are the pics you requested and the parts I used for my retrofit.

-TSX projectors w/ clear lens
-Hella Generation III ballasts
-Philips Ultinon 6000K bulbs
-Gatling gun shrouds (these are the only shrouds that is deep enough to cover the TSX projectors unless you fabricate your own)
-Nissan Butyl tape for sealing the headlight assembly


Yellow arrows = the air breather caps. Just pull these plastic caps off and you'll see a sponge/filter inside. Remove the sponge and drill a hole on the cap, but not too big. Put the sponge/filter back and reinstall the cap.

Red arrow = I don't know how to remove this black cover w/o breaking it, but I had to break it. Under the cover is a headlight adjusting screw. This screw adjusts the headlight beam left to right.

Blue arrow = another adjusting screw that adjusts the headlight beam up or down

Yellow arrows = Hella Gen III ballast. I fabricated a metal cover to prevent the ballast from getting splashed with water or debris. I wanted a stealthy look.

Gatling gun shrouds

Back of headlight assembly after installation

 

[W211_to_T4R]

Oh yeah, I forgot to mention that I also removed the amber relectors for that cleaner look. I also fabricated my own wiring harness so that each projector/bulb has its own relay. I'll take more pics of my wiring harness and relays sometime this week.

 

[Trdsupranick]

Any write up on just opening the headlamp housing?? I would love to remove that ugly yellow reflector.

 

[paraordnance]

Any write up on just opening the headlamp housing?? I would love to remove that ugly yellow reflector.

Its quite easy actually. Preheat your oven to 350 F and turn it off. Wait one minute. Put your headlights on baking sheet and slide them inside on middle rack for 5 minutes. Take out and start prying them apart. Its hard work, you have use some force but it will come apart

 

[MercuryEvo]

looks good and I understand that TSX projectors are better for HID then OEM 06+ But I have an 07 4 runner and I installed a set of 4300K Xenon depot Hid's and I couldnt be more happier. They light the rode up great and I rarely get flashed for my headlights being too bright. They look OEM and were a snap to install. if it were me I'd just buy 06+ headlights and use those with an HID kit. 6k is just too blue for me as well, OEM cars use 4300K which is the brightest, thats why I used those

 

[triguy74]

I don't blame you. Not sure I would take on the retro if I already had projectors. Its been a fun project though and I'm just about done. Life is getting in the way this weekend. In the home stretch, but excited with the results so far.

 

[Trdsupranick]

Really??? Awesome is it that easy? What kind of tool did you use to pry them?
How did you remove the reflectors? How do you "re-seal" the headlamps?

 

[triguy74]

alright, i'm done! it was definitely a project....mainly due to poor timing. i wasn't able to work on it for more than a few hours at a time. people in town...work trips...it all made it last much longer than it should have. i'll post up some pics later...but i'm pretty pleased with the outcome. tonight will be the true test!

my passenger side is still slightly off rotation...i'm going to have to go back in and adjust it. but i couldn't do without my truck for any longer.

 

[W211_to_T4R]

Triguy! I