Very nice. Good write up.
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.
Very nice. Good write up.
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