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  #37  
Old 08-27-2010, 06:58 AM
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Re: Projector retrofit progress

seems to me you guys are way overthinking it..........

not all OEM projectors have self leveling. there is a standard cut-off height of 2.1 inches (might be 2.3) below the level mark at 25 feet. its not a guess, its the standard for projectors.
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  #38  
Old 08-27-2010, 12:29 PM
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Re: Projector retrofit progress

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Originally Posted by robpp View Post
seems to me you guys are way overthinking it..........

not all OEM projectors have self leveling. there is a standard cut-off height of 2.1 inches (might be 2.3) below the level mark at 25 feet. its not a guess, its the standard for projectors.
Thats what I thought but even then, the beams may aim out different ways or be rotationally off of 180 degrees perfectly. I do trust my eyes and all but at the end of the day Id like the to be almost 100% perfect being as once they're set thats it. BUT even more important being the way we mount it so it doesnt ever more in the future due to a pothole or a quick swerve or something like that. I really cant afford to have these things go off line once they're mounted, would break my heart Im sure well be fine though All in time
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  #39  
Old 08-27-2010, 03:10 PM
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Re: Projector retrofit progress

Quote:
Originally Posted by robpp View Post
seems to me you guys are way overthinking it..........

not all OEM projectors have self leveling. there is a standard cut-off height of 2.1 inches (might be 2.3) below the level mark at 25 feet. its not a guess, its the standard for projectors.
I agree with you, but really, there is nothing wrong with a little critical thinking before I get them all sealed up. The issue is not the horizontal axis; that can still be adjusted when the headlights are done. It all deals with getting the vertical (so they are not crossed or too wide) and the rotational (so they are nice and level) correct when mounting the projectors. Factory installed projectors are already aligned in that manner correctly...retrofits are the responsibility of the installer. I'm no professional by any stretch of the imagination! Once they are sealed and installed, I will be using the proper method of aligning them...again, this is only for the horizontal so they aren't too high or too low. Regardless, I have my driver side projector mounted and aimed properly. Now time for the passenger side and I just opened up that housing today. Maybe I can get that one done tomorrow.
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  #40  
Old 08-27-2010, 03:16 PM
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Re: Projector retrofit progress

sounds good. iand i get the point. I wonder if the installer that did mine had a JIG or something that held them straight and level.......
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  #41  
Old 08-30-2010, 02:57 PM
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Re: Projector retrofit progress

ah this all looks quite familiar. In my DubJ I mounted the projectors the same way except I used aluminum spacers. You're off to a great start!

As far as the ripples go, you'll be able to sand them out or use something like bondo to fill any pits/gaps.
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  #42  
Old 08-30-2010, 10:33 PM
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Re: Projector retrofit progress

I tried to look for some aluminum spacers, but all I could find was steel. For some reason, I figured nylon would be better than steel. On the spacers between the projector and the reflector, I used some thicker walled ones so heat should not be an issue. Really, that was my only concern with nylon. I unfortunately am headed home this weekend for my birthday so I won't be getting any more work done for a bit. Well, unfortunately for the retrofit, not for the good times ahead! I'll keep you all posted when I start the passenger side.
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  #43  
Old 08-31-2010, 04:13 PM
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Re: Projector retrofit progress

happy birthday dude, have a good one, ill have a beer for ya :P
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  #44  
Old 09-18-2010, 07:10 PM
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Re: Projector retrofit progress

Wow, it has been a while since I had time to work on these. Its been really busy here and it will continue to be that way for a couple more weeks. But, I was able to get a little bit of work done today. I decided to try something completely different since I had an extra broken headlamp housing...

First off, I did open up that other headlight. Here are some pics showing the tools I used, and where I started to pry. It opened up fairly decent. There are a few areas that will need some epoxy, but its opened and in okay shape. I pretty much used JDubya's write-up, and just bake it at 230 for about 10-15, pry for a couple minutes, bake for 5-10, pry, bake...you get the point.









So, I wanted to try to just mount the projector directly to the back of the housing and do away with the reflector all together. This way, I could still do some type of adjustment once everything was all sealed up. First, I made a couple brackets from some aluminum stock and attached them to the projector. I wanted to increase the spacing of the mounting points since they would be too close to the opening in the back of the housing.







Then I modified the high beam reflector...





I mocked it all up in the housing and I think I really like how its turning out.



I am going to figure out the best way to mount this to the housing so I can still adjust the projector, but I think this is how I am going to end up doing the retrofit. I also need to figure out how I want to make a shroud to cover that whole area. But at this point, its has taken so long that I may as well try a few things. I still have that driver side projector mounted in the reflector. Either way, I need to do this one more time...at least.

Oh, I almost forgot, I made another tool to remove the reflector from the housing! It's really fancy...



Its basically a custom wrench that I could fit under the reflector. I followed the same process for removing the adjuster, but instead of removing the reflector from the remaining ball studs, I unscrewed the one right under the adjuster with this "wrench." Then I only had one more to pry off. I used my other modified brake spoon and the reflector came right off with ease. No broken reflector this time on the passenger side!
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  #45  
Old 09-19-2010, 08:46 PM
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Re: Projector retrofit progress

Quote:
Originally Posted by kerndone View Post
Wow, it has been a while since I had time to work on these. Its been really busy here and it will continue to be that way for a couple more weeks. But, I was able to get a little bit of work done today. I decided to try something completely different since I had an extra broken headlamp housing...

First off, I did open up that other headlight. Here are some pics showing the tools I used, and where I started to pry. It opened up fairly decent. There are a few areas that will need some epoxy, but its opened and in okay shape. I pretty much used JDubya's write-up, and just bake it at 230 for about 10-15, pry for a couple minutes, bake for 5-10, pry, bake...you get the point.









So, I wanted to try to just mount the projector directly to the back of the housing and do away with the reflector all together. This way, I could still do some type of adjustment once everything was all sealed up. First, I made a couple brackets from some aluminum stock and attached them to the projector. I wanted to increase the spacing of the mounting points since they would be too close to the opening in the back of the housing.







Then I modified the high beam reflector...





I mocked it all up in the housing and I think I really like how its turning out.



I am going to figure out the best way to mount this to the housing so I can still adjust the projector, but I think this is how I am going to end up doing the retrofit. I also need to figure out how I want to make a shroud to cover that whole area. But at this point, its has taken so long that I may as well try a few things. I still have that driver side projector mounted in the reflector. Either way, I need to do this one more time...at least.

Oh, I almost forgot, I made another tool to remove the reflector from the housing! It's really fancy...



Its basically a custom wrench that I could fit under the reflector. I followed the same process for removing the adjuster, but instead of removing the reflector from the remaining ball studs, I unscrewed the one right under the adjuster with this "wrench." Then I only had one more to pry off. I used my other modified brake spoon and the reflector came right off with ease. No broken reflector this time on the passenger side!

I love where you're going with this. Glad to see you tossed that reflector too. This setup will be great, full adjustability, best optical performance and cleanest look out there. I think this is going to be an A+ final product! Cant wait.

Only real project left will be your shroud, curious to see what you come up with, im sure it'll be nice though, gl
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  #46  
Old 09-20-2010, 08:22 AM
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Re: Projector retrofit progress

Quote:
Originally Posted by soontobesrt View Post
I love where you're going with this. Glad to see you tossed that reflector too. This setup will be great, full adjustability, best optical performance and cleanest look out there. I think this is going to be an A+ final product! Cant wait.

Only real project left will be your shroud, curious to see what you come up with, im sure it'll be nice though, gl
To be honest, your custom aluminum bracket idea was what put me over the edge. Mine won't be as fancy, but hey, you won't see it anyway. Now, I'm just trying to determine if I will be able to have a rotational adjustment with the way its going to be mounted. Once I figure out the best method, I'll begin work on a shroud...
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  #47  
Old 09-20-2010, 09:09 AM
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Re: Projector retrofit progress

do you really NEED rotational adjustment though? That's great when you're doing a retrofit for someone else and can't test fit and aim them but why not level them then lock the projectors in rock solid?
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  #48  
Old 09-20-2010, 09:37 AM
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Re: Projector retrofit progress

one point jdub, my headlight adjustment can change just by remove/replace my headlights so 'locked in' prolly isnt that great an idea.

also, other mods down stream MAY also affect the headlight aiming.

IMO, you need up and down adjustment. also, I am not sure about removing the reflector..............i guess we'll find out.
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