Guide: real HID projectors in 4x6 headlights

[kikkegek]

I get a lot of questions whenever I tell people about my projector headlights.

I therefor have written this guide, hopefully it will help other that consider upgrading to real HID headlights.

All the details on my build are in this topic on http://www.hidplanet.com
its a wonderfull website with tons of info on LED and HID projectors retrofitting.

my build thread is:
http://www.hidplanet.com/forums/show...n-86-Silverado

I bought most of my parts from http://www.theretrofitsource.com
these guys have the best support and I dont know any other store that has such a wide range of parts and at reasonable price.

I used:
- the "Morimoto Mini H1 projectors"
- Morimoto 3Five 5000K xenon H1 bulbs
- H4 relay harnass TheRetrofitsource
- cheap $15 ballasts from Ebay
- AutoPal crystal clear healights 4x6 I had laying around

the most important pointers:
1. I used AutoPal headlights for two reasons:
A. Mine were metal house. Metal is a little harder to cut, but much stronger and wont break if you beat it or go at it a little to hard. and you can mount the projector easier on metal. I just used a load of JB Weld to glue the two together.
B. these AutoPal headlights had clear glass lenses. for the best output you would want to use thin acrylic like lenses, but glass is much stronger, wont scratch so easy and will not break so fast when removing after cooking it in the oven to open up the housing.





2. cook the headlight in the oven
check out this video

http://www.youtube.com/watch?v=anN0vYBj6Uo

3. cut the reflector part so the projectors fits


4. I had to use a extra piece of plastic to put the projector further back, otherwise the lense would not fit back on. Other form a new lense by "vacuum forming" ...I wanted to reuse the original




!!! before you glue the stuff together, try the projectors in your car to see if they are level. search on HID planet for "aiming projector" and you'll find all kinds of tips on how to do this.

5. trim edges and glue together using JB Weld:


6. I painted the reflector because they were old and the chrome was bad. some keep the chrome. some paint the flat black...if I open them up again I will paint the flat black. make sure you use heat resistant paint like VHT or similar.



7. mount shroud and mount the lens back on using butil or some heat resistant RTV to make sure you get an airtight fit.






there you go




output pics:



cruise video:

http://www.youtube.com/watch?v=9lACmnqGZ5A

PM me if you have any questions.

[wraprail]

Finally someone shows the "Mysterious" projector headlights that only the "proud few" have!
Thanks!
btw...why not use your high beams for added light? Looks like you have then covered.

[kikkegek]

Originally Posted by wraprail

Finally someone shows the "Mysterious" projector headlights that only the "proud few" have!
Thanks!
btw...why not use your high beams for added light? Looks like you have then covered.

thanks man!

I have just painted some sealed beams I had laying around flat black. I wanted a more overall black look and didnt use these high beams anymore. the highbeams from the projector are so bright that there is absolutely no need for extra high beams. and they are to high for fog lights. I might remove them all the way and maybe make air intakes at that point in the grill or just close the bezel with some acrylic sheet.

[wraprail]

Maybe look for a 2 lamp grill and use 5x7 lights?

[kikkegek]

Originally Posted by wraprail

Maybe look for a 2 lamp grill and use 5x7 lights?

that was the first thing I looked into, but I'd have to change the hood also wouldnt I?

[ProStreet83C10]

nope....hood stays the same - 83 C10 pictured below

[wraprail]

^^

[kikkegek]

Originally Posted by ProStreet83C10

nope....hood stays the same - 83 C10 pictured below

cool!

well, already did the retro, so good info for others, but I wont go there anymore.

just curious. you need to change the whole front radiatorsupport right?

[INSIDIOUS '86]

Mine didnt have many pictures of the build. I got another set ready to make though by using wrecking yard parts. Wraprail I'm pretty sure I showed you all te documentation I had
Nobody should go his without these!


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[Redcap]

Great thread. I might tackle this project in the spring!

[Pop's C-10]

Originally Posted by kikkegek

cool!

well, already did the retro, so good info for others, but I wont go there anymore.

just curious. you need to change the whole front radiatorsupport right?

yes..you need to change the core support

[kikkegek]

Originally Posted by Pop's C-10

yes..you need to change the core support

I was afraid of that. I might keep an eye open if they tear a chevy apart over here. parts like that arent too easy to get over here

[INSIDIOUS '86]

You know there are high beam projectors that shot a more focused beam further out especially good for seing deer on a wooded highway in the night or mountain roads.
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