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Old 07-15-2019, 08:50 PM   #1
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2013 Focus Projector Retrofit Questions

Howdy All,

I purchased some aftermarket headlights with projector housings for my Ď13 Focus. They look great, and I wanted to upgrade to HID headlights. However, the projector housings in the headlights are halogen projectors and the H1 HID bulbs are too long. They hit the part of the projector that cuts the beam for a low beam pattern. This also makes a bunch of dark and bright spots in my low beam pattern. Leaving me with poor visibility at night. Hopefully, I can return them.

So. I am thinking about running the Projector retrofit route. I saw a post on here about someone selling a retrofitted projector headlight set up they made for their Focus because they were trading in their Focus. I really liked the look and have always wanted to try my hand at a projector retrofit project, but I need a question or two answered first.

I want to keep my factory headlights stock in case I need to swap back for any reason. So, I need a new set. I have seen on eBay and Amazon, some cheap headlights that use H7 bulbs for the low beam and others that use H11 bulbs. How well do they hold up? Can I use a set of those or should I invest a little more and purchase some OEM headlights for this project? My concern is weather or not the cheaper ones will handle the extra weight of a projector and still hold the headlight alignment.

Another thing I should note, is that the H1 Mini projectors that I plan on using, state in the specs section on the Retrofit Source website that H4 and H7 headlight housings require little to no modification to the reflector bowl what so ever. So, I would prefer to go that route and get a set that uses H7 bulbs if possible.

Thanks in advance!

Lord Snax


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Last edited by Lord Snax; 07-15-2019 at 08:53 PM. Reason: grammer corrections
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Old 07-15-2019, 10:28 PM   #2
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Aftermarket housings should hold the weight of the projector just fine. The only thing I'd be worried about is the lenses on them fading or "hazing". I had a set of aftermarket projector housings and the lenses didn't hold up too well. After about a year the clear coat on the lens started to peel off causing them to haze up. That's when I ditched them and retrofitted my OEM H11 housings. The only thing I had to do is grind down one little tab in the bulb opening to get the Mini H1 projector to fit. I may have also had to enlarge the bulb opening as well but I can't remember for sure.

One benefit of the aftermarket housings though is that they tend to be easier to open up because they use softer sealant than the OEM housings.
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Old 07-16-2019, 08:52 PM   #3
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Quote:
Originally Posted by EvilEric19 View Post
Aftermarket housings should hold the weight of the projector just fine. The only thing I'd be worried about is the lenses on them fading or "hazing". I had a set of aftermarket projector housings and the lenses didn't hold up too well. After about a year the clear coat on the lens started to peel off causing them to haze up. That's when I ditched them and retrofitted my OEM H11 housings. The only thing I had to do is grind down one little tab in the bulb opening to get the Mini H1 projector to fit. I may have also had to enlarge the bulb opening as well but I can't remember for sure.

One benefit of the aftermarket housings though is that they tend to be easier to open up because they use softer sealant than the OEM housings.
Thanks for the info. You got me thinking. I might just go ahead and retrofit my factory headlights anyway. Since the protectant on the lenses is better. I’ll just pick up a cheap set as a backup to swap to if I need to.
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Old 07-17-2019, 09:05 PM   #4
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I’m about to start a retrofit of Morimoto Mini D2S 5.0s into aftermarket Amazon headlights. Just ordered all the parts. I’m not too concerned about the lenses. Those $15 3M Headlight Restoration kits work wonders if they do start to haze. I also apply Blue Magic Headlight Sealer periodically to all my lights.

One concern is neither the stock, nor aftermarket lights have horizontal adjusters.

Last edited by E365/5; 07-17-2019 at 09:23 PM.
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Old 07-18-2019, 03:39 AM   #5
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Originally Posted by E365/5 View Post
Iím about to start a retrofit of Morimoto Mini D2S 5.0s into aftermarket Amazon headlights. Just ordered all the parts. Iím not too concerned about the lenses. Those $15 3M Headlight Restoration kits work wonders if they do start to haze. I also apply Blue Magic Headlight Sealer periodically to all my lights.

One concern is neither the stock, nor aftermarket lights have horizontal adjusters.
Interesting, all the aftermarket headlights I have been looking at do have a horizontal adjustment screw.
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Old 07-27-2019, 01:31 PM   #6
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Quote:
Originally Posted by E365/5 View Post
Iím about to start a retrofit of Morimoto Mini D2S 5.0s into aftermarket Amazon headlights. Just ordered all the parts. Iím not too concerned about the lenses. Those $15 3M Headlight Restoration kits work wonders if they do start to haze. I also apply Blue Magic Headlight Sealer periodically to all my lights.

One concern is neither the stock, nor aftermarket lights have horizontal adjusters.
How is the project coming along? I'm thinking about going with some D2S projectors as well, but I'm concerned about space. Is there enough room for a D2S projector in the headlights?
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Old 07-28-2019, 12:29 AM   #7
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How is the project coming along? I'm thinking about going with some D2S projectors as well, but I'm concerned about space. Is there enough room for a D2S projector in the headlights?
Making progress. These are the 2015+ headlights, so the 2012-14s might be different.

The halogen low bulb is a H11 and the threaded mounting shaft on these Morimoto Mini D2S 5.0 projectors are so large youíd need to pretty much grind out the entire H11 socket and thereíd be no ďmeatĒ left to mount the new projectors. So, I had to build up the area first with Gorilla Epoxy Stick (just like JB Weld Steel Stik). I sanded down the backside of the reflector bowls first and put a coating of JB Weld Plastic Weld epoxy down first because I didnít like how the Epoxy putties stuck (it didnít stick too wonderfully) to the reflector bowl plastic. I tried a few brands/types. Then I sanded down the PlasticWeld epoxy and stuck the Gorilla putty to that. A good combo in my limited testing.

Then I drilled out the hole for the projector and used a Dremel and sanding drum to fine tune the hole size. I also sanded down the shiny side of the reflector because some areas were thicker than others. This allowed the reflector to sit in a tad further and expose more threads of the projector mounting shaft.

Then I used a belt sander to flatten out the backside. I just eyeballed ďlevelĒ based on the reflector bowl mounting surfaces.

I also drilled a little hole for the bi-xenon solenoid wires and clearanced a tiny bit on the bottom of the reflector bowl to accommodate the projector.

The next step will be to mount the assemblies without the lens covers and lock down the rotation of the projectors and fine tune the horizontal aim. Iím pretty sure Iíll be able to adjust that with washers where the reflector bowls mount.

Iíve only eyeballed-it, but it appears they are mounted deep enough to fit the lens covers back on.
Attached Thumbnails
2013 Focus Projector Retrofit Questions-53edea74-52ba-49e1-9b29-5930e15819e2.jpg  

2013 Focus Projector Retrofit Questions-4d9031bd-2ca7-4294-ba5c-ec192fd678d9.jpeg  

2013 Focus Projector Retrofit Questions-2cbbaf27-640b-4c2e-972f-0cd708893267.jpg  

2013 Focus Projector Retrofit Questions-5c464a23-f5db-457f-9527-0bd9006290d8.jpg  

2013 Focus Projector Retrofit Questions-d5341819-6a67-4512-93c4-2b3e85a4ce19.jpg  

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Old 07-28-2019, 12:31 AM   #8
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Hereís a little hole I made in the bottom of the reflector to accommodate some of the projector.
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Old 07-28-2019, 08:15 AM   #9
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Quote:
Originally Posted by E365/5 View Post
Making progress. These are the 2015+ headlights, so the 2012-14s might be different.

The halogen low bulb is a H11 and the threaded mounting shaft on these Morimoto Mini D2S 5.0 projectors are so large you’d need to pretty much grind out the entire H11 socket and there’d be no “meat” left to mount the new projectors. So, I had to build up the area first with Gorilla Epoxy Stick (just like JB Weld Steel Stik). I sanded down the backside of the reflector bowls first and put a coating of JB Weld Plastic Weld epoxy down first because I didn’t like how the Epoxy putties stuck (it didn’t stick too wonderfully) to the reflector bowl plastic. I tried a few brands/types. Then I sanded down the PlasticWeld epoxy and stuck the Gorilla putty to that. A good combo in my limited testing.

Then I drilled out the hole for the projector and used a Dremel and sanding drum to fine tune the hole size. I also sanded down the shiny side of the reflector because some areas were thicker than others. This allowed the reflector to sit in a tad further and expose more threads of the projector mounting shaft.

Then I used a belt sander to flatten out the backside. I just eyeballed “level” based on the reflector bowl mounting surfaces.

I also drilled a little hole for the bi-xenon solenoid wires and clearanced a tiny bit on the bottom of the reflector bowl to accommodate the projector.

The next step will be to mount the assemblies without the lens covers and lock down the rotation of the projectors and fine tune the horizontal aim. I’m pretty sure I’ll be able to adjust that with washers where the reflector bowls mount.

I’ve only eyeballed-it, but it appears they are mounted deep enough to fit the lens covers back on.
Wow! I didn’t think that a D2S retrofit would be that involved. It’s no longer a question of if I can. It’s a question of do I have the time and the work space.

I was initially thinking about a D2S retrofit because I wanted to run 55w HIDs. However, the Mini H1 projectors from The Retrofit Source (TRS) are 35w HIDs only, and the D2S are 35w or 55w. Since this is my first retrofit project, I think I will run with the Mini H1 projectors from TRS.

The downside is that I already have a 55w H1 HID kit. The TRS support guys said, “I can use 55w HIDs, but they would not honor the warranty on the Mini H1 projectors. It would damage the inside of the projector after a year or so. Causing poor lighting performance.”

On the upside TRS support guys said that I can trade my 55w ballasts out for 35w ballasts and opened a RMA ticket for it.
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