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  #13  
Old 08-14-2010, 11:47 PM
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Re: Projector retrofit progress

sounds good! ive been wanting to do this, but im probably gonna sell the jeep...
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  #14  
Old 08-15-2010, 04:36 PM
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Re: Projector retrofit progress

So far nice man, i like that mounting option versus using adhesive only, may go that route as well. I agree about aiming as well if you get the cutoff where you want sideways its gonna be fine because you cant control that really anyway can you besides keeping it straight and as close to 180o in the reflector?

And you're using 08+aftermarket housing ehhh, dint notice till those pics, you get them off AM-auto or some other source? And which projectors are those, nice cutoff/beam pattern as well! - Anthony
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  #15  
Old 08-15-2010, 11:49 PM
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Re: Projector retrofit progress

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Originally Posted by soontobesrt View Post
So far nice man, i like that mounting option versus using adhesive only, may go that route as well. I agree about aiming as well if you get the cutoff where you want sideways its gonna be fine because you cant control that really anyway can you besides keeping it straight and as close to 180o in the reflector?

And you're using 08+aftermarket housing ehhh, dint notice till those pics, you get them off AM-auto or some other source? And which projectors are those, nice cutoff/beam pattern as well! - Anthony
When you mount the projector, you have three "planes" to align. The horizontal alignment can be adjusted using the stock mechanism, so getting it close is going to be sufficient. I have mine set at the height of the halogen beam, so I know I will have plenty of adjustment to dial it all in when I am finished. The next one is the vertical alignment; it cannot be adjusted after everything is sealed. This one is to ensure your headlights are pointed straight ahead and not crossed or pointing away from each other. To achieve this, I just put a reference mark on the bottom of the reflector housing. As long as the flat part on the front of the projector is parallel, I should be good to go. The last is the rotational aspect, and like the vertical adjustment, it cannot be changed once everything is sealed. This one is pretty simple, if your cutoff is angled, the rotation is off.

That is an '08+ OEM housing I bought from a member here. They don't actually make any aftermarket options for the newer style yet. The projector is an FX-R using 35W Morimoto ballasts and a 5000K Morimoto D2S capsule.
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  #16  
Old 08-16-2010, 12:15 AM
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Re: Projector retrofit progress

I like how you are making a step by step process for people to follow. I will definitely have to do this to my jeep, most likely just the low beams though. Great work!
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Old 08-16-2010, 11:37 AM
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Re: Projector retrofit progress

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Originally Posted by kerndone View Post
When you mount the projector, you have three "planes" to align. The horizontal alignment can be adjusted using the stock mechanism, so getting it close is going to be sufficient. I have mine set at the height of the halogen beam, so I know I will have plenty of adjustment to dial it all in when I am finished. The next one is the vertical alignment; it cannot be adjusted after everything is sealed. This one is to ensure your headlights are pointed straight ahead and not crossed or pointing away from each other. To achieve this, I just put a reference mark on the bottom of the reflector housing. As long as the flat part on the front of the projector is parallel, I should be good to go. The last is the rotational aspect, and like the vertical adjustment, it cannot be changed once everything is sealed. This one is pretty simple, if your cutoff is angled, the rotation is off.

That is an '08+ OEM housing I bought from a member here. They don't actually make any aftermarket options for the newer style yet. The projector is an FX-R using 35W Morimoto ballasts and a 5000K Morimoto D2S capsule.
I was gonna say, I thought those were 08+ OEM but I really didn't think they could be opened that well. Cant believe no one makes them yet, must not be cheap enough to be profitable maybe due to the projectors? Looks nice man, It's exciting watching the culmination of a lot of hard work, time and money. Keep patient Im sure these things will be top notch!
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  #18  
Old 08-17-2010, 11:44 AM
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Re: Projector retrofit progress

Got a little bit more done today before work. I made some nylon spacers that I will epoxy to the back of the reflector so I can tighten down some nylock nuts on a flat surface. I still need to make some sort of spacers for the inside on the right side of the projector so it cannot move inwards. I doubt it would, but I may as well put something there as a stop. I'm not sure what I can use the fill in the holes, I would like to use some kind of sandable epoxy so I will have to see what is available...any suggestions?

Here is what the back looks like with the spacers mocked up.







I will be trimming them down as well as the screws so it doesn't stick out so far. I hope the get it completely mounted and start the shroud this weekend. I did receive another passenger side light yesterday so I will begin work on that sometime in the near future. The housing has a small crack which will need to be repaired and I am going to have to swap lenses with my other spare. However, it should turn out just fine. I'll document the repair process too.
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  #19  
Old 08-18-2010, 02:40 PM
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Re: Projector retrofit progress

Cool, I like the spacers and as far as for the front, are you referring to the the area inside the housing between the projector and the back of the reflector? Once you torque it don't I cant see it moving but as you said its a good idea to fill that space. Im sure they make some of the expandable foam stuff that hardens up and is heat resistant I believe to as I have seen/found tons of it while I was doing my SRT conversion.
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  #20  
Old 08-18-2010, 04:41 PM
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Re: Projector retrofit progress

looks great! But I highly agree with rob! DO NOT PUT THE BALLAST INSIDE IT! if you have to mount it to the bottom of the outside of the headlight!
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  #21  
Old 08-19-2010, 12:03 AM
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Re: Projector retrofit progress

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Originally Posted by soontobesrt View Post
Cool, I like the spacers and as far as for the front, are you referring to the the area inside the housing between the projector and the back of the reflector? Once you torque it don't I cant see it moving but as you said its a good idea to fill that space. Im sure they make some of the expandable foam stuff that hardens up and is heat resistant I believe to as I have seen/found tons of it while I was doing my SRT conversion.
I am concerned with the area between the screw and the back of the reflector. Without anything between that area, the projector would technically be able to move towards the reflector. My upper left mount touches the reflector, so that will be solid, but the rest have a gap. While tightening down a bolt on the back side will keep it from moving forward, without anything on the other side, it could move backward.

And thanks for posting in my thread Steve, its good to have feedback from a professional like yourself!



The gray part is the projector, the red is the screw, blue are the locking nuts, orange is the spacer on the back and black is the reflector. Right now, the green is showing what I mean. If nothing is between the projector and the reflector, the whole thing could move towards the reflector...I hope this illustrates what I am trying to say! I think two or three solid mounting points will be more than enough. With one solid already, I should only need one or two spacers to satisfy me!
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  #22  
Old 08-19-2010, 12:20 AM
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Re: Projector retrofit progress

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Originally Posted by kerndone View Post
I am concerned with the area between the screw and the back of the reflector. Without anything between that area, the projector would technically be able to move towards the reflector. My upper left mount touches the reflector, so that will be solid, but the rest have a gap. While tightening down a bolt on the back side will keep it from moving forward, without anything on the other side, it could move backward.

And thanks for posting in my thread Steve, its good to have feedback from a professional like yourself!



The gray part is the projector, the red is the screw, blue are the locking nuts, orange is the spacer on the back and black is the reflector. Right now, the green is showing what I mean. If nothing is between the projector and the reflector, the whole thing could move towards the reflector...I hope this illustrates what I am trying to say! I think two or three solid mounting points will be more than enough. With one solid already, I should only need one or two spacers to satisfy me!

hmmm I see what you are saying, is the projector pushed all the way in to the point it touches the reflector? Is there play in it as it sits now? If could see it being an issue but even then you could apply the similar spacer concept, maybe just a few nuts on it instead of a spacer? But I honestly think the pressure of the one nut on the spacer out back holding it together would be enough to hold it tight! I mean what forces are being applied to the projector ever, minus some up and down when you hit bumps but that is solved with the mounting setup. Under hard braking maybeee, but I doubt its enough to even slightly move it. I agree this should be as solid as possible but at the same time I think your 4 mounts and spacers will be PLENTY to hold these baby's in place. If there is play in it though due to the shape of the projector in the reflector then maybe the spacer thing will need to be done. Im assuming you couldn't fit them on the front or you would have? Or was it a look type of thing? The shroud will cover all that as well so you could probably do anything to keep it from moving back what little distance is there. A close-up would really help me see what you are dealing with, Im sure we could think of something simple and easy if you haven't already haha. Keep us posted!
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  #23  
Old 08-19-2010, 01:01 AM
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Re: Projector retrofit progress

Yeah, its not that there will ever be any pressure applied to the front, its simply due to the vibration of hitting bumps. I considered just using a nut, and I might do something like that with a nylock nut in a position that it will bottom out against the reflector. There is not a cosmetic function to it; it is simply to keep the projector from moving when hitting bumps. I will try to take a pic this weekend when I work on it. Unfortunately, waiting for the halos is really going to be the critical step in this project. I might put the shrouds on hold until both of my projectors are mounted. Really, if I am going to wait until October for the halos, there isn't a rush to finish one before I start the other. I definitely have the time!
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  #24  
Old 08-19-2010, 10:09 AM
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Re: Projector retrofit progress

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i would never put theballast inside. if it goes bad, you mUST open the lights again.
I agree with NOT putting the ballast inside the housing. Ballasts create a decent amount of heat. If you seal them in the housing, the heat has no good way to escape and will make the ballast prone to failure.
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