Retrofit Projectors

[D3f4ult]

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.

[ColoFreeJeeper]

Very nice. Good write up.

[D3f4ult]

Very nice. Good write up.

Thanks I appreciate it. Next in the chute will be HID addition!