How To: HID+Projector Retrofit on a 100 Series.

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2000UZJ said:
Does anybody know if these will fit? I'm not scared of a dremel to trim the grill. I don't want to replace the sheet metal.

http://www.ebay.com/itm/TOYOTA-LAND-CRUISER-06-07-HEADLIGHT-UNIT-PAIR-SET-NEW-Maxzone-/160763885247?pt=Motors_Car_Truck_Parts_Accessories&hash=item256e4636bf&vxp=mtr
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They will not fit without metal work. I haven't seen just what the extent of the metal work is though. It is the one part of the 06 updates to our rig that has never been very clear.
 
Mxndrnks said:
They will not fit without metal work. I haven't seen just what the extent of the metal work is though. It is the one part of the 06 updates to our rig that has never been very clear.
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Just texted AATLXXSISXIS5555 or whatever that username is (Shane). From what I can gather you will need to replace the lower valence trim piece (under the headlights) and the grill. I think I may pull the trigger on the headlights and see if I can't trim the grill slightly. The inside of the fender has a tab that needs to be trimmed (or cut) as the light has the integrated blinker,
image-98461400.jpg
 
2000UZJ said:
Just texted AATLXXSISXIS5555 or whatever that username is (Shane). From what I can gather you will need to replace the lower valence trim piece (under the headlights) and the grill. I think I may pull the trigger on the headlights and see if I can't trim the grill slightly. The inside of the fender has a tab that needs to be trimmed (or cut) as the light has the integrated blinker,
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That is my understanding as well. Robred has a write up on his site as well if you choose to support that site. There were a couple write ups here too...

If you take it on, do a proper write up with pics (especially the fender) so we can have it on mud.
 
Mxndrnks said:
That is my understanding as well. Robred has a write up on his site as well if you choose to support that site. There were a couple write ups here too...

If you take it on, do a proper write up with pics (especially the fender) so we can have it on mud.
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I think I am going to try it. Should be ordering within the next 2 weeks. I am a moderator on Rob's website, I've just been slammed with work and school that I have not had time to make it over there as much as I should or want.

I will document it over here with photo's
 
2000UZJ said:
I think I am going to try it. Should be ordering within the next 2 weeks. I am a moderator on Rob's website, I've just been slammed with work and school that I have not had time to make it over there as much as I should or want.

I will document it over here with photo's
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I know this was months ago, but I thought you hadn't tried it yet.

TLCFAQ.com has the parts list of everything you need. There is more metal work than you'd think. The tab needs to be folded back on the fender, but the entire headlight opening on the fender needs to be trimmed back about 1/8" or so. I trimmed mine less than that and there's still a slight gap between the headlight and fender. The lower portion of the fenders that connects to the lower front valence needs to be cut for the new headlight/trim support piece to fit. I'll take some pictures and show you what I mean.
 
Yeah, it's definitely not "simple" and "straight forward". You will need to drill out some spot welds, install new support brackets, install new panels under the lights, use a grinder on your fenders, etc, just to support the light/grille swap. Also, as a side note, the 06/07 lights and grille MUST be paired together. The 06-07 grille will not work with earlier lights, and the earlier grilles will NOT work with the newer lights - at least not well enough to leave it that way. The 06-07 lights will not physically fit into the openings of the 98-05 fenders. You have to take a angle grinder and remove about 1/8" of material along the inside edge of the opening in order for the lights to work. It's not hard, but it can be fairly unnerving as you're grinding on $400+ fenders and hoping you don't mess up.

Too bad you can't get the eBay lights anymore that were direct drop-in replacements to the 98-05 cruisers but looked identical to the 06/07 design.
 
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Great write up I just finished mine last night. I did a couple things differently, I didn't need to cut any of the original light socket, I had enough thread sticking out to put the nut on. I also used a slightly different and much less expensive retro kit I got off eBay. Either way the results are awesome, I will get some beam shots up tonight.

http://www.ebay.com/itm/151100240408

image.jpg
 
Nice CK, that looks well done and I'll bet the light out put is very impressive. Love HID's when run correctly with a projector.
 
Looks good. So there is zero cutting the housing to fit these projectors? Thanks
 
ckkone said:
Some more pics:
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Do you have plans (where you sourced which items, etc) to do any type of write up on this mod yet, CK? If you don't, I'm sure lots of us would appreciate one. Nothing like true HID. That pic of the projection and cut off looks solid! Great work! :-)
 
bluecruiser said:
Looks good. So there is zero cutting the housing to fit these projectors? Thanks
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No I did not need to cut the housing, I did trim the bezel inside the lens to make sure there was enough vertical adjustment.

Elijah said:
Do you have plans (where you sourced which items, etc) to do any type of write up on this mod yet, CK? If you don't, I'm sure lots of us would appreciate one. Nothing like true HID. That pic of the projection and cut off looks solid! Great work! :-)
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Parts list:

Pair 2.5" Mini Bi-Xenon HID Projector Kit $47.00

H1 Xenon kit of your choice

Black Polyurethane Sealant

I basically followed the instructions in this thread..

1. Remove lights (also remove 9005/9006 mounting rings and rubber seals)
2. Bake in oven at 220 for ~9 minutes
3. Separate lens from housing
4. Remove, notch and reinstall bezel
5. Install HID projector
6. Temporarily reinstall headlights to make sure beam cutoff is level
7. Remove headlights and clean
8. Bake lens and housing again to soften the factory sealant (220 for maybe 7 min) and reattach lens to housing.
9. I added a bead of black polyurethane sealant around the light just to make sure it was sealed. (a little of this goes a long way)
10. Reinstall and aim headlights

A couple notes:

1. leave the factory sealant, do not scrape it off
2. You can route the high beam wires through the lower existing hole from the diffuser.

I wish I had done this sooner, for $90 and a couple hours its a no brainer.
 
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Ck, definitely interested in this since it's sickly cheap. How have your eBay ballasts and lamps held up so far?
 
Muddy Bean said:
Ck, definitely interested in this since it's sickly cheap. How have your eBay ballasts and lamps held up so far?
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They suck. I took off some ddm tuning ballasts and an eBay harness and went with the retrofitsource stuff this weekend. The improvement in output is significant. The cheap ballast don't put out 35 watts. Pay the extra upfront IMO.
 
Well it will be "Only the Best" for most of this crowd for their expeditions from petrol station to petrol station... But I got the ballasts about 4 years ago off eBay and just had to order new H1 bulbs. So far everything is working great, no regrets.
 
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