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Old 05-01-2007, 02:57 PM   #1
BigSho
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Default Hid Retrofit Tutorial

HID lights should never be used in a reflective housing made for halogens...and since many of you asked, here is the write up of how to retrofit projectors into saturn housings

Materials needed:
-2 Acura TSX projectors $160 on ebay
-2 new headlamp housings...i prefer the ebay ones they are easy to get apart $140
-2 phillips d2s hid bulbs $50-100 depends where you get them
-2 HID kit ballasts made for 9006 headlights (its better to use OEM...but i didn't want to deal with relay harness and all that)(100-150$)
-2 hid d2s amp connectors to go from the bulb to the ballast ($15 on ebay)
-2 clear headlight lenses (up to you)
-screws, jbweld,masking tape, fiberglass resin, nuts, washers, dremel with cutting tool, clear silicone sealant, and an oven

Step one...
Take all the clips off of the headlamp housings and preheat oven to 275 degrees for 10 minutes. Once it is heated, turn the oven off and lay down a baking sheet and set the housings ontop of it. Let them sit in there for about 10 minutes and take out. Take a flat head screw driver and pry the lense off of the housing gently...re-heat if needed.

Step 2.
Measure the TSX projector and cut the back and bottom of the housings.
When finished it will look like this.

there needs to be a groove cut down the middle about 2 inches long as well at the bottom...you'll see it where my thumb is



step 3.
Now you will slide the projector in and trim any fins on the projector that prevent it from sliding it back and sitting level (the cutoff shield on the projectors always are on the bottom....the light inverts through the lense)


it will look like this from above (minus the hid ballast connector)



Once everything is sitting level and flush, you will drill 4 holes in the housing (through the mounting posts on the tsx projectors)

They are circled in red


Insert long screws and put washers and nuts on the other side of the housing and tighten everything down. Once it is tight and straight, put some JB weld on the nuts so they dont unscrew

Step 4. Mix the fiber glass I use the elmers stuff from homedepot


and seal up the gaps in the back
it will look like this once its covered


cover the seams again once dried with clear silicone

These housings are too narrow for shrouds to fit properly...so i masked off the housing and painted the projector (taped off lense) and the chrome behind the low beam black so it doesn't stick out and look ugly


Once this is done...its time to seal up your housing lense...take out any bulbs in the projector and preheat oven to 275 degrees for 10 minutes. Turn oven off and stick the headlight housings in the oven for 10 minutes.

Take the housings off and firmly push the lenses back in (you basically are re-using the original sealant). Attach the clips and seal any other gaps with clear silicone.

Once its all sealed it will look like this (with clear lenses)


once everything is together....put the bulb back in the projector (return wire facing down) and clip it shut.
Attach the AMP connector to the bulb and seal it with clear silicone so water doesn't get in anywhere and let it dry 24 hours. If you need to ever change the bulb, you can get the silicone off by pulling it with some pliers.

Ballasts will need to be installed...(reverse the wires on the stock 9006 connectors, our cars headlights are negative switched and then find someplace to mount the ballasts.

More to come once i get them on my car.

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Old 05-01-2007, 06:55 PM   #2
Monkius
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Default Re: Hid Retrofit Tutorial

where did you get the clear/smooth headlight lenses?
which ebay "ones" (headlamp housings)?

edit: I just added all the prices up, and it totals like $600. Ouch!

Last edited by Monkius; 05-01-2007 at 07:04 PM..

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Old 05-01-2007, 09:41 PM   #3
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Default Re: Hid Retrofit Tutorial

Quote:
Originally Posted by Monkius View Post
where did you get the clear/smooth headlight lenses?
which ebay "ones" (headlamp housings)?

edit: I just added all the prices up, and it totals like $600. Ouch!
the lenses are custom made. Stock lenses with the front cut off and the clear part vaccuum formed. I had them done for me.

And yes...its around $600...but you gotta do it right or go home.

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Old 05-02-2007, 12:11 AM   #4
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Default Re: Hid Retrofit Tutorial

this is sticky worthy.

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Old 05-02-2007, 05:54 AM   #5
Jim Dunlop
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Default Re: Hid Retrofit Tutorial

Nice tut!

$600 is a small price to pay for serious enthusiasts who want to blind the |-|3|_|_ out of the guy in front of them, as well as feel like they have luxury cars.

LOL, do it right or SIT DOWN!

My Cool Blue headlights are good enough for me though given my budget.

...
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Old 05-02-2007, 08:52 AM   #6
BigSho
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Default Re: Hid Retrofit Tutorial

Quote:
Originally Posted by Jim Dunlop View Post
Nice tut!


$600 is a small price to pay for serious enthusiasts who want to blind the |-|3|_|_ out of the guy in front of them, as well as feel like they have luxury cars.

LOL, do it right or SIT DOWN!

My Cool Blue headlights are good enough for me though given my budget.



i dunno if you're joking about the blinding part

but these are made to not blind people. There is a sharp distinct cutoff and the only thing oncoming traffic will see is the color flicker at the top of the cutoff when they are aimed properly (2 inch drop from level of headlights every 25 feet).

If you wanna blind people, you put in a HID drop in kit that scatters light everwhere its not needed. And when behind a car, at one car length distance, the lights should be level with the back bumper. So its not blinding anyone.

once again...

this would be a picture of glare caused by someone using HID in a reflector housing
(This is a 12,000k color temp kit pic taken from hidplanet....see all the light strayed off where it shouldn't be?)


Now compare it to some 4300k color temp Hid's in a tsx projector
(pic taken from haknslash at hidplanet)--as you can see, there is no stray light anywhere its not supposed to be

the flicker you see is from the color band at the top of the beam so you dont get the full 3200 lumens of white light coming at your eyes.

What do halogens get....less than 1200 usable lumens i think. A properly setup HID system with 4300k lights will put out 3200+ lumens of light on the ground in a non-blinding fashion.....that is all

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Old 05-03-2007, 01:58 AM   #7
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Default Re: Hid Retrofit Tutorial

It seems like you could snag a lot of parts from the junk yard, and save some money on it.

...
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Old 05-03-2007, 03:04 AM   #8
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Default Re: Hid Retrofit Tutorial

im getting my headlamps retroed here: www.jwhiteslights.com $425 w/ tsx projectors, custom shrouds and bezels. woot! ive seen his work in person. good stuff. but as of right now.....im being a ric0rz with an 6000k pnp kit. oh noez!

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Old 05-03-2007, 11:22 AM   #9
BigSho
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Default Re: Hid Retrofit Tutorial

Quote:
Originally Posted by EDUBB View Post
im getting my headlamps retroed here: www.jwhiteslights.com $425 w/ tsx projectors, custom shrouds and bezels. woot! ive seen his work in person. good stuff. but as of right now.....im being a ric0rz with an 6000k pnp kit. oh noez!
not bad price at all. I rolled around with a 6000k pnp kit as well before i did my retro! Jwhite seems like a good guy too....i see him him post a lot of usefull info on HIDplanet

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Old 05-05-2007, 10:59 AM   #10
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Default Re: Hid Retrofit Tutorial

alright, got em installed and semi-aimed

here's the pix






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Old 05-05-2007, 03:25 PM   #11
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Happy Re: Hid Retrofit Tutorial

Look nice, and really bright too.

...
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Old 05-05-2007, 04:14 PM   #12
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Default Re: Hid Retrofit Tutorial

I like how they look head-on. If someone saw you coming, they would have no idea what kind of car it was. Then when you pull up and they see it's a Saturn...

...
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Old 05-05-2007, 06:10 PM   #13
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Default Re: Hid Retrofit Tutorial

yeah it looks pretty dang slick at night if i say so myself

not to mention- the fact that you see the two beams and no glare...so no blinding of other drivers

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Old 05-05-2007, 07:44 PM   #14
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Default Re: Hid Retrofit Tutorial

Well done sir. Much respect!

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Old 05-06-2007, 10:57 AM   #15
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Default Re: Hid Retrofit Tutorial

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Originally Posted by Abe95SC2 View Post
Well done sir. Much respect!
thanks! It was well worth it

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Old 05-11-2007, 10:10 PM   #16
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Default Re: Hid Retrofit Tutorial

updated output shots
here are the output/cutoff pix
i have them aimed according to "B" on this chart


I didn't aim them like C because idiots around here highbeam everyone with HIDs around here. Doesnt matter if its a acura tl, land rover, bmw or anything that comes with HID from the factory. No matter where you go, they sit and flash every HID equipped car that goes by.

So i figured i'd get off their nerves and lower the driver side beam a bit.

Anyway..onto the pix
at/beneath the cutoff


some color at 25 ft


cutoff





on a hill


COLOR:







on a hill again


thanks

Lemme know what you think!

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Old 05-12-2007, 11:12 AM   #17
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Default Re: Hid Retrofit Tutorial

Nice man, this makes me really want to finish mine now.

So did you ever get the lense worked out? I think i might call some plastic places around me and see if they would be able to make me some clear lenses.

Well i'll have to finish the engine rebuild before i start on anything else.

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Old 05-12-2007, 01:12 PM   #18
BigSho
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Default Re: Hid Retrofit Tutorial

Quote:
Originally Posted by petdmc View Post
Nice man, this makes me really want to finish mine now.

So did you ever get the lense worked out? I think i might call some plastic places around me and see if they would be able to make me some clear lenses.

Well i'll have to finish the engine rebuild before i start on anything else.
yeah, i fiberglassed the pieces together then covered it all with pvc glue.

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Old 05-12-2007, 09:54 PM   #19
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Default Re: Hid Retrofit Tutorial

great work, sho.

has anybody ever told you that your garage has too much stuff in it?

...
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Old 05-13-2007, 12:33 AM   #20
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Default Re: Hid Retrofit Tutorial

Quote:
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great work, sho.

has anybody ever told you that your garage has too much stuff in it?

Thanks! You can only fit so much in a 1 car garage you know .

O well, i have the oldest car in the family and i park in the garage...cant complain

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