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Old 05-08-2017, 11:30 AM
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New Headlight Retrofit

This project starts with another WK owner shipping me their headlights. USPS ended up treating one of them pretty badly so he ended up getting a set of Black replica lights. I opened both sets, swapped projectors and installed demon eyes in the black set. The reason for swapping projectors was b/c the replica's aren't as good/reflective as the OEM ones.

I offered the owner a little money for the broken OEM ones and now I have a set of opened OEM lights to mess with. My goal at the end of this is to have a great performing set of lights that look OEM+, are plug and play and will be available for sale. So if you're interested shoot me a PM and we can talk about it!

For reference here are the set of lights I built for my own WK:
HID/LED Headlight Project

Build begin:

OEM lights use a sealant known as permaseal. It is much much tougher than the butyl that holds replica lights together. My method for opening them was as follows:
240 Fahrenheit for 20 minutes
+ some strength with reverse pliers
+ Occasional reheat (~4-5 mins)
= Opened lights

Here's some shots of the damage:

My plan is to go with a D1s bixenon projector in the low beam area. This will allow the owner to utilize an OEM D1s bulb & OEM Valeo Ballast.

Low Beam:

High Beam:

Some of the additional idea's that I have had are:
- Etched lenses
- Paint OEM Shroud
- Line-X OEM Shroud
- Hydrodip OEM Shroud
- Paint/Vinyl wrap OEM amber reflector
- Passive demon eye (black/red/other)
- LED fog lights in the High Beam reflector

I'm open to other suggestions if anyone has one that sounds cool!

I temporarily secured the mounts by melting the plastic around them. I will need to pick up some epoxy/glue that works with polypropylene.

Too bad this one didn't hold while I was working on removing the permaseal

Speaking of permaseal I didn't have too much trouble removing it. A pick and some linesmen pliers (a little easier to handle than a hammer) worked to get it out. Needle nose pliers helped pull it out. I did get a little overzealous a few times and ended up punching holes in the back of the channel... No big deal since it will have retrorubber there. It's not totally removed yet. I had some issues with the funky corner but I'm going to work on it again this Friday.

Funky Corner

Hoping to have more progress later this week. Enjoy this for now and again if you are someone who is interested shoot me a PM and we can talk

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Old 05-15-2017, 05:58 AM
Join Date: Sep 2013
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Re: New Headlight Retrofit

Progress from this weekend:

​Projectors got here on Thursday. The advertised D1s projectors came with D2s mounts as well. This is good because I may be able to abandon the whole D1s idea and go with a D2s setup.

This is ideal for someone who already has HID's in reflector housings as they should be able to use all their current hardware. If you have HID's in reflector housings and would like to upgrade to real HID output for a low cost shoot me a PM.

Here are the mounts. D1s vs D2s (also D2h will work):

Size vs the OEM (pictured is a OEM replica). They are pretty close in length. The BiXenon is a little wider and also uses a 3" clear lens:

Had to do a little trimming to fit the Projector into the OEM bracket.

They look good in there! Had to drill one mount hole by the solenoid (as seen in pic#4):

Nut & bolt worked well and I got to use one of the OEM torx screws in the new hole:

I still need to work on clearing out more of the permaseal. The 2nd headlight was fighting me so I decided not to force it. Hopefully more updates soon!
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