2005 Dual Halo Projector Retrofit Project

[Jgrove998]

Hey all! Well this thread is going to be about retrofitting a better projector assembly into my black housing dual halo projector headlights I purchased from k2motors.

To start, my opinion on the headlights themselves. The fitment is perfect for my 2005 sedan. The connectors also fit perfect with no problems. It is a simple source and ground connection for the halos and 4 LED bulbs in the eyebrows. I wired them to my running lights. The low and high beams run H1 bulbs. The projector low beams are where the problem starts. The light output is decent but not what I was expecting. The cutoff is OK but not super sharp and there are the infamous flip ups on either side of the light output. High beams are very bright! The sealant of the lights seem OK but after 3 months of having them all 4 of the LED bulbs in the eye brows burned out. Overall, I really like the lights, I just wish the output from the low beams was better.

After a month of having the lights I purchased a Apexcone HID kit with 6000K bulbs. Wiring was soooo easy but the H1 bulbs didn't fit quite right so I had to grind off a bit of the plastic around the bulbs to get them to fit right. Light output was a little better but I still was not happy.

So to fix the problem: a new projector housing! I got really lucky to find a pair of Acura TSX projectors on eBay that i got for $112.50 plus 9.99 shipping.

I will document my progress in this thread! Any tips, suggestions or constructive comments are welcome!

Justin

[Sponsor]

[Jgrove998]

So today I started to take the headlights apart. Of course you have to bake the headlights in the oven. I cooked mine at a temperature of 200 degrees Fahrenheit for 5 mins at a time. I reheated the headlights 4 times to get the seal apart. I broke the top apart first then pried the sides and bottom apart. I am happy with the results and I did not damage the headlights at all.

One question: How am I going to clean off all the old sealant and what sealant should I use to reseal them?

Now for pictures of what I'm working with!

What I started with.......


After breaking the headlight open.....




Notice the cutoff shield and how it is curved on the edges. Could that be causing the flip ups on the outsides of the light outputs?




Here is the bag-o-parts for each headlight....


Here is a close up of the cutoff shield....



Here is the reflector for the low beams. Why is it a oval shape?


Here is the projector lens....


This is the mounting location I'm working with, shouldn't be too bad!


The high beam reflector....


The wires from the headlight connector were so simple: 1 ground split for both lights and separate power wires.


This is the LED holders/connectors. No wires were broken. Maybe the LED's weren't rated for 12v use? I was thinking of replacing the white LED's with yellow ones. What do you think?


The halo's were simply wired with a male/female connector into the inverter box thing.





I won't be able to work on these anymore until I get the new projector housings.

I'm excited!

[slowduratec]

Good luck your gonna have fun!!! and a very good write up so far. If you already know, which you prob do those d1s projectors and the the light connector is a d2s which wont go together.

[Jgrove998]

are the Valeo projectors I'm getting D1S? not D2S? I thought i had it straight! thanks for letting me know!




Ok, did some research. The Valeo projectors I was looking at getting are D1S. I have no need for the D1S since I have a aftermarket HID kit. The D2S has the same mounting flange just without the ignitor built on the end of it. I must come up with a way to secure the D2S bulb but it will fit for sure. I saw pictures on other forums for HID retrofitting. Thanks slowduratec!

[Jgrove998]

double post.

[SPIman2.0]

wow...... those are going to be BAD!!! Can't wait to see the final product....

[Jgrove998]

Yes....I really hope it turns out as well as i hope!

[captcurt_18]

thats sick. how much is this costing you?

[Jgrove998]

new projector housings - $122.50 plus shipping (Acura TSX Projectors) <---from eBay

D2S converter cable - $15

New D2S bulbs - 6000K - $45

(Converter cable and new D2S bulbs purchased from "The Retrofit Source")

[slowduratec]

yea didn't know if you knew already, didn't want to see you get something and not be right.