Tyler James Inc's Ultimate '01 SR5

[4Runner4Leon]

Here we go again!

I love my 4.0's, but I saw NHK came out with some huge 3.2" Projectors, and I had to try them [emoji23]

Sweet, just in time for my planned retrofit. I'm guessing these are them - https://www.lightwerkz.net/index.php/components/hid-projectors/bixenon-g5exl-projectors.html ? Would love to see results.

BTW, not to threadjack, but I am having a mental block on how you guys wire the bi-xenon projectors, since our truck are set up to have either high or low beams on, but not both. Do you get a special harness, or make your own mods to have the high beam open the flapper while keeping the lights on using the low beam?

 

[Tyler James Inc]

...I am having a mental block on how you guys wire the bi-xenon projectors, since our truck are set up to have either high or low beams on, but not both. Do you get a special harness, or make your own mods to have the high beam open the flapper while keeping the lights on using the low beam?

You'll want to get a relay harness to run your headlights. On the input side, it's specific to the H4 connector we have. On the output of the relay harness, it has the connectors that plug into the ballasts, and 9006 connectors for the high beam solenoids. The Morimoto projectors come with the flapper wires terminated, and a 9006 body to plug the pins into once you fish them through any grommets you might be using. The NHK wires have a connector that plugs into the flapper, but the other end of the wires have nothing. You have to buy a 9006 connector for it to plug into your relay harness.
Let me know if that doesn't make sense; I'm always happy to help [emoji1360]

 

[4Runner4Leon]

You'll want to get a relay harness to run your headlights. On the input side, it's specific to the H4 connector we have. On the output of the relay harness, it has the connectors that plug into the ballasts, and 9006 connectors for the high beam solenoids. The Morimoto projectors come with the flapper wires terminated, and a 9006 body to plug the pins into once you fish them through any grommets you might be using. The NHK wires have a connector that plugs into the flapper, but the other end of the wires have nothing. You have to buy a 9006 connector for it to plug into your relay harness.
Let me know if that doesn't make sense; I'm always happy to help [emoji1360]

That totally makes sense Tyler, thanks. Where do you get the relay harness, TRS? Or another place? I was all set to grab the Morimoto D2S's, but now I'm intrigued by the NHK (bigger must be better). When are you going to put them in and show us how they compare?

 

[Tyler James Inc]

That totally makes sense Tyler, thanks. Where do you get the relay harness, TRS? Or another place? I was all set to grab the Morimoto D2S's, but now I'm intrigued by the NHK (bigger must be better). When are you going to put them in and show us how they compare?

Anytime.
I prefer LightWerkz.com over TRS, but both sell the bi-xenon relay harness you need.
If you happen to have Instagram, look up lightwerks.
Here is a post showing the G5-EXL-

I can't say better is better. I just wanted to try them!
The 4.0's have a threaded shaft, so those are much easier to install vs the "nut and bolt method" you have to use with the G5 projectors.
Here's some output shots of mine-

As you can see, the step is pretty large. It's nice to know you aren't blinding oncoming, but the step is a little extreme IMO. They really are great projectors though. They have a super wide pattern.

The step is right on the center line in that last pic.

They really are amazing, and I'm not sure having these G5-EXL's being 3 times brighter is really going to be a good thing [emoji23] We'll see.
My pics are all with Hylux 45w ballasts and NHK 5500k bulbs.

 

[rkntoy]

You'll want to get a relay harness to run your headlights. On the input side, it's specific to the H4 connector we have. On the output of the relay harness, it has the connectors that plug into the ballasts, and 9006 connectors for the high beam solenoids. The Morimoto projectors come with the flapper wires terminated, and a 9006 body to plug the pins into once you fish them through any grommets you might be using. The NHK wires have a connector that plugs into the flapper, but the other end of the wires have nothing. You have to buy a 9006 connector for it to plug into your relay harness.
Let me know if that doesn't make sense; I'm always happy to help [emoji1360]

I wish I understood what you are saying. Then maybe I could put a set together.

 

[4Runner4Leon]

They really are amazing, and I'm not sure having these G5-EXL's being 3 times brighter is really going to be a good thing [emoji23] We'll see.
My pics are all with Hylux 45w ballasts and NHK 5500k bulbs.

That is some serious light output, wow. These shots are all low-beam?

I can see the large step possibly becoming annoying over time.

So which do you prefer, the NHK or the D2S's???

 

[Tyler James Inc]

That is some serious light output, wow. These shots are all low-beam?

I can see the large step possibly becoming annoying over time.

So which do you prefer, the NHK or the D2S's???

Yes!! All low beam. They're seriously life changing man. My headlights sucked so bad. It makes driving at night so much more enjoyable!
I really can't say which I prefer, as I haven't ran the NHK yet. I'm hoping to have them built this weekend. I'll definitely be posting results as soon as I get them done!

I wish I understood what you are saying. Then maybe I could put a set together.

Oh it's easy! You need a set for sure.
I don't love the look, but function over form wins on this one for me.

 

[thezentree]

I prefer LightWerkz.com over TRS

Why? I plan on ordering projector mod parts this summer but I’m a total newb to that.

 

[rkntoy]

Oh it's easy! You need a set for sure.
I don't love the look, but function over form wins on this one for me.

OK. Need some time at the Beer Den so I can put my shopping list together.

 

[cblock406]

Any pics of the new headlights? Would love to see them.

 

[BrianSD_42]

Interesting, first time I've seen the Lighthouse brand. I did a TRS retrofit recently with the Mini D2S 4.0 and unlike their previous versions the step was overly large as well. I wonder who is stealing from who lol. They both are manufactured China right. That box plastered with German also has Chinese on it. That doesn't make a lot of sense if it was actually German. These are just my observations. I have no horse in the race. Sorry if it seems off topic.

 

[Tyler James Inc]

OK. Need some time at the Beer Den so I can put my shopping list together.

Yes. Always down I'd be happy to build you a set if you aren't interested in putting headlights in your oven, opening them up, etc.

Why? I plan on ordering projector mod parts this summer but I’m a total newb to that.

It's kind of a "I like to support the little guy" deal, but there is more to it than that. I have delt with both, and I prefer going through Caesar(LightWerkz).

Interesting, first time I've seen the Lighthouse brand. I did a TRS retrofit recently with the Mini D2S 4.0 and unlike their previous versions the step was overly large as well. I wonder who is stealing from who lol. They both are manufactured China right. That box plastered with German also has Chinese on it. That doesn't make a lot of sense if it was actually German. These are just my observations. I have no horse in the race. Sorry if it seems off topic.

It only seems off-topic because I have never heard of "Lighthouse", and am not following what you're talking about. My current headlights are D2S 4.0's- just like you have- and those are what I was talking about when I was talking about the large step being annoying.
The new G5-EXL's I am putting in my new set are made by NHK, as are the bulbs I've been running in the 4.0. NHK makes good stuff, but I'm sure it's made in China. They haven't copied any Morimoto projectors as far as I've seen, as they don't offer one that's directly comparable. I'm certain if NHK was made in Germany, it would say on the box. It may be misleading to say German lighting brand, but they don't claim to be made in Germany.

Any pics of the new headlights? Would love to see them.

Just did a test fit last night! Since I have to use the nut-and-bolt method to mount the EXL, I gotta mount them on the rig to make sure they're positioned and clocked properly.
Here's the 4.0 on the driver side-

And the G5-EXL on the pass side. The tape is the pass side 4.0 to compare step and position-

And both-

Under construction mode-

 

[4Runner4Leon]

And both-

That's a great side by side comparison, I like the smaller step!! How is the pattern otherwise, is it comparable to D2S? The NHK seems to have a bit of a brighter hotspot under the cutoff compared to the D2S, I wonder how that would project onto the road ahead.

 

[Tyler James Inc]

That's a great side by side comparison, I like the smaller step!! How is the pattern otherwise, is it comparable to D2S? The NHK seems to have a bit of a brighter hotspot under the cutoff compared to the D2S, I wonder how that would project onto the road ahead.

Exactly. It's much more intense. I'm real excited for it! The EXL has been shown to put out THREE TIMES as much light as the 4.0 on the lux meter with the same bulb. Much more intense- not quite as wide as the 4.0.

 

[thezentree]

Y
It's kind of a "I like to support the little guy" deal, but there is more to it than that. I have delt with both, and I prefer going through Caesar(LightWerkz).

Makes sense. I'd not heard of LightWerkz before you mentioned them. I'll have to check them out.

 

[4Runner4Leon]

Exactly. It's much more intense. I'm real excited for it! The EXL has been shown to put out THREE TIMES as much light as the 4.0 on the lux meter with the same bulb. Much more intense- not quite as wide as the 4.0.

That's super interesting! Can't wait to see the light output on the road (I'm thinking of putting this on my birthday wish list since my wife is asking for ideas ).

Edited: looking at the website description, it sounds like these require custom mounting, not the "thread-on" approach of the D2S. Would be interested in seeing how you mounted them!

 

[infantry503]

The EXL has a really nice cutoff. I am interested in seeing what the final verdict will be. I might do the switch as I do not like the huge step on my D2l

 

[Tyler James Inc]

The EXL has a really nice cutoff. I am interested in seeing what the final verdict will be. I might do the switch as I do not like the huge step on my D2l

I'm assuming yours are the Morimoto 4.0 as well? They really are great projectors, and I could keep them and be very happy with them. One thing that puts them high on the charts is the threaded shaft(for ease of install). I'll touch on that below.

That's super interesting! Can't wait to see the light output on the road (I'm thinking of putting this on my birthday wish list since my wife is asking for ideas ).

Edited: looking at the website description, it sounds like these require custom mounting, not the "thread-on" approach of the D2S. Would be interested in seeing how you mounted them!

Yes, that's right; the G5-EXL are not built with threaded shafts. That's what I was referring to when I have talked about "nut and bolt mounting method" above. It's not horrible if you have the jig/template to drill the housing out, but it's definitely more work than the threaded shaft. There is much more aiming/aligning to be done with the nut and bolt method too- that's why I installed it temporarily last night.
You can see the bolts in this pic-

The template/drill jig-

Being a clear poly, it's kind of hard to see in the pic. It also is not self-aligning in any way. You have to position it and clock it just right for the holes to be placed correctly.

 

[4Runner4Leon]

Yes, that's right; the G5-EXL are not built with threaded shafts. That's what I was referring to when I have talked about "nut and bolt mounting method" above. It's not horrible if you have the jig/template to drill the housing out, but it's definitely more work than the threaded shaft. There is much more aiming/aligning to be done with the nut and bolt method too- that's why I installed it temporarily last night...

The template/drill jig-

Being a clear poly, it's kind of hard to see in the pic. It also is not self-aligning in any way. You have to position it and clock it just right for the holes to be placed correctly.

Thanks, that's very clear. Did you make your own template/jig?

I once tackled putting the Morimoto Mini H1's into a Chrysler T&C reflector, which I am convinced is world's smallest reflector. Of course I could not use the threaded shaft of the Mini H1, and had to fabricate custom mounts, plus cut away half the reflector. So I hope that the nut and bolt method in the large 4Runner headlight will be easy by comparison (fingers crossed).

Here are some pics of that project, still gives me the willies (sorry for threadjack):

 

[BrianSD_42]

Sweet, just in time for my planned retrofit. I'm guessing these are them - https://www.lightwerkz.net/index.php...rojectors.html ?

Oh sorry man. I meant lightwerks. I think it autocorrected, plus it wasn't your comment. So we both have the Mini 4.0s made by Morrimoto which is owned by TRS. Designed here in US and manufactures in China.