Xenon Projector Upgrade.

38,025

137

3

Introduction: Xenon Projector Upgrade.

If it breaks, fix it. If it works, take it apart. If it can be bought, make it. If it doesn't exi...

Want to upgrade to xenon's bulbs or HID's?

Pic 1: You should have the right optics.

Pic 2: Or your car is going to look like this to oncoming traffic.

Pic 3: Xenon projectors tested with an LED Flashlight - No Glare

Skill Level: Intermediate

Parts: Morimoto Mini H1 Projectors
            Xenon Depot H1 Bulb & Ballast set
           USDM Projector style headlights
            two 3"x 4" PVC general purpose drain
            Stretch and seal tape





Step 1: Remove Headlights

Open hood
Remove grille (4 clips & 3 screws)
Remove headlights (3 Screws)

Step 2: Gather the Materials & Parts

Pic 1:
Two 3" x 4" General purpose PVC Drain
Stretch & Seal tape for waterproofing.

Pic 2:
I chose the drain as the diameter matched the original headlight housing perfectly.
Also, the top of the drain provided a flush mounting surface for the projector housings

Pic 3: Disassemble your headlight housings

Step 3: Making the Housing.

Pic 1:  The reason for choosing the general purpose drain was:
            PVC - can withstand temperature fluctuations
            Durable 
            Waterproof
            The top of the drain provided a flush mounting surface for the projector housings
            I chose the drain as the diameter matched the original headlight housing perfectly.

Pic 2: Using a table saw cut the drain to height.
           (Take off 1mm of material every pass if using a table saw)
           You can also use a rotary tool or hand file.

Pic 3: Trim PVC piping to have a step.
           This allows the housing to fit within the front of the housing.

Pic 4: A look from inside.

Step 4: Cutting the PVC Drains to Size

Pic 1: After fitting the projector into the new PVC housing
           I had to reduce PVC Drain housing height
           This reduces the gap between projector and refractor

Pic 2: Took a few quick measurements and figured it out.

Pic 3: New lenses!

Pic 4: Broken tab.

Pic 5: Shaped a piece of aluminum to fit within tab area.

Pic 6: Bent the piece to fit into the broken tab area. (follow up with epoxy)

Pic 7: PVC Drains cut to size
    

Step 5: Mounting the Projector

Pic 1: Finally after another trimming, I find the right height.

Pic 2: Cut a circular disk that fits within the drain (to replace the original drain mesh)
           Use original mounting points for the drain mesh to mount the circular disk
           Drill a 1" hole to fit the projector housing in.

Pic 3 - Projector housing mounted

Pic 4: Click tabs were made to click fit the new housing into the original

Pic 5: The click tabs lock into the inner lip of the original housing

Pic 6: Loaded!

Pic 7: Finish the housing for the other side

Step 6:

Pic 1: Nice.... no glare.

Pic 2: Quick test indoors.

Pic 3: Done!!

Pic 4: Testing!

Share

    Recommendations

    • Creative Misuse Contest

      Creative Misuse Contest
    • Fix It! Contest

      Fix It! Contest
    • Metalworking Contest

      Metalworking Contest

    3 Discussions

    Great write up, and very creative use of plumbing materials. I've been wanting to convert my motorcycle lights to projector for a while(currently an offender of HID bulbs in halogen housings) and I think I might do it this winter now that I've got a solid base to go off of.

    its nice. but the bad part is , its forbidden for using in cars in our country