This weekend's project was to retrofit my headlights and foglights with HID units. I used the following parts, all from TheRetrofitSource!
Headlights:
-Acura TSX projectors
-TSX-R/FX-R clear lenses
-Morimoto D2S Elite Kit with 35W XB ballasts, HD relay
-Osram Xenarc 66240 Nightbreaker (4200K)
-Morimoto Retrorubber Butyl Glue
-2x 80mm Housing caps
Foglights:
-Morimoto H3C Elite Kit with 35W XB ballasts, XB 3000K bulbs and HD relay
I was able to use TRS's 25% off code so the above order cost me ~$500 shipped to my door.
The project took me roughly 8 hours of work over 2 days. The majority of the time was spent trying to center the new TSX projectors into the cut stock mounting plate.
I began by removing and opening up the stock projectors. 7 minutes in the oven at 270* was perfect for opening them up. The lens came off pretty easily.
Then I disassembled the headlight and cut the stock projector. You need to cut the housing in order to use the stock mounting points. Try and cut it as flush as possible. I cut it from the outside but if I were to do it again, I would cut it from the inside of the projector. I used a dremel with a metal cutting disc.
I mocked up the TSX projectors and used double sided tape and such to tack the projector in place to test alignment and to level them. I tested with the stock TSX projector lenses in case I got them smudged or chipped since I was mounting and unmounting them on the truck with no lens on.
Then once I was happy with the alignment, I drilled holes in the mounting plate to attach the projector housing. Then I placed the new Retrorubber butyl glue and baked the new lens back on. Once again, I did 7 minutes at 270*. Then I cut the 80mm rubber caps to pass the wires through and mounted them up. I had to cut the bottom of the cap because the D2S bulbs use the ignitor on the back of the bulb and the wire points straight down.
Output shots! I need the bulbs to break in and I need to work on aligning the bulbs some more. They are aligned well vertically but need to work on aligning them horizontally. The pictures are taken with different exposures to capture the light differently. I'll try and get some foglight only output shots tomorrow night.
The left projector got a little tilted somehow during final mounting so I'll need to go in and fix it another time.
Next up is to clean up my hideous headlight lenses and ceramic coat them to prevent further oxidation. Thinking I'll tackle this next weekend.
