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Thread: Retrofit Projectors

  1. #1
    Junior Member D3f4ult's Avatar
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    Default Retrofit Projectors

    Parts:

    7" Ebay round "projector" headlights
    Projector headlights from junkyard (aftermarket from an Integra)
    Sensor safe black RTV
    Aluminum tape
    Construction Grade Adhesive
    Dremel


    Prep:

    I placed both of them in the oven on BAKE 375 degrees for 12-14 minutes. I then used a small flat head screwdriver and CAREFULLY, removed the glass lens.

    Tear Down:

    Then I measured 50 times and cut 75, seriously though, I measured multiple times and cut probably three until I got a very tight fit.

    IMG_20100827_000740.jpg

    Then I placed the projector housing inside the newly cut hole. Below is a comparison of cheap E-bay (RIGHT SIDE) and retrofitted projector housing (LEFT SIDE).

    IMG_20100826_235454.jpg

    Again projector left, e-bay right

    IMG_20100826_235526.jpg

    Aiming and Fitting:

    I placed the lenses inside a Bench Vise, pointed at the wall.
    I twisted and turned the projector until I got a flat, direct beam
    I then used sensor safe RTV to seal around the crack
    Used Aluminum Tape wrapping the projector to the headlight housing.

    Wrap up:

    Then I painted the chrome reflector to match the Jeep
    Resealed the lenses with construction grade adhesive I got from Lowes
    Let everything dry overnight

    Install:
    Installed and aimed

    Outcome:
    IMG_20100827_190707.jpg

    Actually impressed. Extremely clean cutoff from a true projector. I can't beat it for a total of 30 dollars and a half day of work.

    They don't shake or rotate. The aluminum tape is near permanent, I've been through water crossings and off-roading with no issues.

  2. #2
    Free at last... ColoFreeJeeper's Avatar
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    Default

    Very nice. Good write up.

  3. #3
    Junior Member D3f4ult's Avatar
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    Default

    Quote Originally Posted by ColoFreeJeeper View Post
    Very nice. Good write up.
    Thanks I appreciate it. Next in the chute will be HID addition!

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