Hoser, my main purpose here was better lighting and not looks, so I don't care that much about the chrome. But I will wait and see what happens and keep you posted.
Your Hi-beam has the chrome reflector bowl too. Once that is shot, you could lose much of the output. Also, could you give the dimensions of your projector, maybe a diagram. That way these guys could try and find a suitable or maybe smaller projector for an easier retrofit. Thanks for taking the time to do the write-up.
Oh indeed. But on the other hand what's the problem. If anything happens to the hi-beam, I will just pop in a hi-beam projector. I hve become very good at extreme sawzalling
And one more thing. I am using the stock harness. HIDs draw an enormous amount of power at startup (the first 10-20 seconds) so everyone says that running a stock halogen harness is bad. It can melt, switches can melt etc... But I've done some thinking (strange huh?) and realized that the headlights have a separate relay so the switch is not in danger. The cables are also quite thick. I took the risk and so far nothing is melting.
I didn't want another harness as I like simplicity and not a bunch of cables under the hood.
In order to make my headlights as stock as possible I used the bulbs from the original ones and (you guessed it) sawzalled the plastic bases/connectors. Then I soldered the connectors to the bling light cables and now I can connect the lights as if they were stock.
I will measure the unused projector today and give the exact dimensions, so that you guys can have even cooler lights in the future.
Yes, that's probably a hella model. Give me some time and maybe I will find some pics of it. I would have used it if I could buy it, but unfortunately it's not available here.
This is awesome work......Thanks As soon as we hear about the correct measurements going to get this project going. I got these measurements from HID planet for the different projector sizes..... Any thoughts to what version will fit in the ebay projector housing? My problem is I am sending these to an Address in the U.S. so I have to figure everything out before hand. Not sure if the Lexus LS430 projectors would fit but they give a nice wide beam.
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PLEASE READ: Length was measured with a D2S in there and is measured to the end of the bulb. Diameter was measured for shroud fitting purposes and is a measure right on the edge, around the glass lens housing.
Hella 2nd Gen Bi-Xenon (aka E55):
Diameter = 79.80mm
Height = 96.95mm
Width = 106.15mm
Length = 163.35mm
Length(seat of the lens to possible mounting holes) = 58.80mm
Length(possible mounting holes to end of bulb) = 83.90mm
Width(between top mounting holes) = 77.25mm
Width(between bottom mounting holes) = 93.25mm
Height(between mounting holes) = 58.90mm
Stanley Bi-Xenon (aka TL):
Diameter = 80.25mm
Height = 95.95mm
Height(with solenoid) = 117.15mm
Width = 111.60mm
Length = 171.85mm
Length(seat of the lens to mounting holes) = 56.90mm
Length(seat of the lens to end of solenoid) = 89.25mm
Length(mounting holes to end of bulb) = 95.80mm
Width(between top mounting holes) = 82.55mm
Width(between bottom mounting holes) = 90.85mm
Height(between mounting holes) = 71.40mm
Bosch Bi-Xenon (aka E46):
Diameter = 78.30mm
Height = 84.10mm
Width = 105.00mm
Length = 166.95mm
Length(seat of the lens to mounting holes) = 66.65mm
Length(mounting holes to end of bulb) = 80.70mm
Width(between top mounting holes) = 82.00mm
Width(between bottom mounting holes) = 95.10mm
Height(between mounting holes) = 62.10mm
Valeo Bi-Xenon D1S:
Diameter = 82.55mm
Height = 96.00mm
Width = 106.20mm
Solenoid(sticks out by) = 9.40mm
Solenoid Length(from mounting holes) = 69.05
Length = 156.20mm
Length(seat of the lens to mounting holes) = 49.45mm
Length(mounting holes to end of bulb w/D2S) = 84.25mm
Width(between top mounting holes) = 72.20mm
Width(between bottom mounting holes) = 70.95mm
Height(between mounting holes) = 78.20mm
Infinity FX35/45 Bi-Xenon (aka FX):
Diameter = 69.20mm
Height = 105.10mm
Width = 111.80mm
Length = 150.70mm
Length(seat of the lens to mounting holes) = 54.60mm
Length(mounting holes to end of bulb) = 72.10mm
Mounting hole distances are not measured beacuse most people
would make their own and cut-off stock brackets.
Land Rover LR3 Bi-Xenon (aka LR3):
Diameter = 78.30mm
Height = 95.30mm
Height Trimmed = 88.50mm
Width = 126.30mm
Width Trimmed = 121.70mm
Length Total = 141.75mm
Length(seat of the lens to mounting holes) = 45.50mm
Length(mounting holes to end of bulb w/D2S) = 96.25mm
Width(between top/bottom mounting holes) = 63.20mm
Height(between mounting holes) = 76.80mm
Hella Low Beam (from pre-2002 Audi A6):
Diameter = 71.90mm
Height = 103.65mm
Width = 110.55mm
Length = 159.00mm
Length(seat of the lens to mounting holes) = 55.40mm
Length(mounting holes to end of bulb) = 84.45mm
Width(between top mounting holes) = 67.85mm
Width(between bottom mounting holes) = 82.35mm
Height(between mounting holes) = 87.95mm
Audi A4 Valeo DOT D2S Low Beam:
Values are approximate
Height = 85.00mm
Width = 100.00mm
Length = 150.00mm
Length(seat of the lens to mounting holes) = 60.00mm
Width(between mounting holes) = 60.00mm
Height(between mounting holes) = 72.00mm
Thank you LiquidKernel for Valeo measurements
Mitsubishi Lancer Evo8 Low Beam:
Diameter = 85.10mm
Height = 86.00mm
Width = 109.50mm
Length = 171.40mm
Length(seat of the lens to mounting holes) = 61.75mm
Length(mounting holes to end of bulb) = 77.30mm
Width(between mounting holes) = 98.15mm
Height(between mounting holes) = 28.35mm
Mazda 3 Low Beam (Stanley):
Diameter = 85.10mm
Height = 98.50mm
Width = 116.50mm
Length = 167.00mm
Length(seat of the lens to mounting holes) = 53.00mm
Length(mounting holes to end of bulb) = 87.70mm
Width(between mounting holes) = 97.85mm
Height(between mounting holes) = 68.50mm
High beam bracket would be cut-off on this projector, comes integrated OEM.
Lexus RX330 Low Beam (Non-AFS, w/Subaru Legacy Shield):
Diameter = 77.10mm
Height(with Shield) = 109.50mm
Height Bowl = 96.70mm
Width Bowl = 106.50mm
Length = 139.20mm
Length(seat of the lens to mounting holes) = 48.60mm
Length(mounting holes to end of bulb) = 90.60mm
Width(between top mounting holes) = 33.75mm
Width(between bottom mounting holes) = 40.50mm
Height(between mounting holes) = 98.80mm
This projector usually comes with a cut-off shield that has OEM mounting brackets integrated. Most would usually cut these off and make their own holes for mounting. Subaru Legacy Halogen projector is almost idnetical to this Xenon projector. We used cut-off shield from the Legacy projector as it is smaller and has mounting holes built-in. All measurements are to reflect shield replacement. Height and width measurements are also given for an actual Xenon reflective bowl.
Acura TSX Low Beam (Stanley):
Diameter = 71.05mm
Height = 85.30mm
Width = 120.80mm
Length = 156.45mm
Length(seat of the lens to mounting holes) = 42.00mm
Length(mounting holes to end of bulb) = 96.95mm
Width(between top mounting holes) = 100.45mm
Width(between bottom mounting holes) = 103.45mm
Height(between mounting holes) = 41.50mm
Honda S2000 Low Beam (Koito):
Diameter = 71.70mm
Height = 105.60mm
Width Trimmed = 113.50mm
Length = 135.30mm
Length(seat of the lens to mounting holes) = 41.40mm
Length(mounting holes to end of bulb) = 93.90mm
Mounting hole distances are not measured beacuse most people
would make their own and cut-off stock high beam bracket, width is measured as trimmed.
Lexus SC430 Low Beam (Koito):
Diameter = 71.70mm
Height = 100.30mm
Width = 130.00mm
Width Trimmed = 125.30mm
Length = 138.30mm
Length(seat of the lens to mounting holes) = 43.90mm
Length(mounting holes to end of bulb) = 94.40mm
Mounting hole distances are not measured beacuse most people
would make their own and cut-off stock mounting brackets, width is measured as trimmed because it could be trimmed a bit.
Lexus LS430 Super Wide Low Beam (Stanley):
Measurements for this projector are provided as "naked" - shroud removed, OEM mounting bracket removed, supplemental reflector was included in measurements. Also, assumed some "fat" (eg.: AFS spindles) would be trimmed. Where it says "trimmed", this is only an assumptive place where it was deemed best to trim without too much sacrifice. Some people will choose to trim more or not to use the whole or most of the shroud that gives this projector most of it's bulk. Please remeber that this is a very large projector/shroud combination.
Diameter = not measured as this projector comes with it's own shroud
Height = 117.05mm
Max Width = 134.32mm
Trimmed Width = 125.80mm
Width Bottom Reflector = 124.10mm
Length = 154.75mm
Length(tip of the lens to possible mounting holes) = 55.95mm
Length(possible mounting holes to end of bulb) = 98.80mm
Lexus LS430 shroud measurements:
Max Height = 143.62mm
Trimmed Height = 131.70mm
Max Width = 173.15mm
Trimmed Width = 154.30mm
Overall Diameter=Dt, Curved Diameter=Dc(dia. of the curved part of the lens, without the flat edge), Center Thickness=Tc, Edge Thickness-Te. All Measurements are in Millimeters
I am currently away from home so I will be able to give the measurements within 7-8 days.
I sort of forgot about this thread. You know, all the threads where people just put HID bulbs into the stock reflector get pages of replies and lots of enthusiasm.
But my thread received a few replies (although very positive) so I thought that either my mod is too boring to discuss or too ideal to add anything
Anyway, wait a few days and I will do as promised, I will measure the original projectors that I removed.
Great writeup. I have HIDs retrofitted on my Passat and I can tell you guys a couple things that may help your project if you want to undertake this.
1. I saw a comment on the plastic housing and questions about pitting, etc. A company called Xpel makes headlight film to prevent this. Check them out here: http://www.xpel.com/
2. HID ballast and bulb kits can be bought here for single filament (no high and low beams in the same bulb) for $56! http://vvme.com/
I am shopping for an 80 right now and this will be my first mod. I can't live without them now that I am used to them. Everything else is just cheap. I was even going to try and fit them to my 60 before I decided to sell it.
I have two questions: 1) what feature(s) do the halogen projectors have that makes them hated by others, 2) why didn't you just use HID bulbs in the halogen projectors?
Hi there, I just returned home and will do as I promised, which is to give the measurements of the projector I replaced and I will also tel Knorrena some basics. Just wait until I unpack and eat something.
knorrena, putting an HID bulb (capsule) behind a Halogen projector is akin to putting on somebody else's prescription glasses. An HID capsule does not put out light the same way a halogen bulb does. Some claim decent results with the HID bulb behind a halogen projector. However, the results will never be optimal.
There are also "rebased" HID bulbs that claim to position the HID capsule at the "correct" focal length for use with Halogen projectors. I'm not really sold on that though. Go with the HID projector that is designed and tuned for HID capsules.
knorrena, putting an HID bulb (capsule) behind a Halogen projector is akin to putting on somebody else's prescription glasses. An HID capsule does not put out light the same way a halogen bulb does. Some claim decent results with the HID bulb behind a halogen projector. However, the results will never be optimal.
There are also "rebased" HID bulbs that claim to position the HID capsule at the "correct" focal length for use with Halogen projectors. I'm not really sold on that though. Go with the HID projector that is designed and tuned for HID capsules.
They are only that, claims. Rebased HID lamps still have the wrong length and shape of the arc, and in the real world are almost never properly aligned with the focal point.
For those that don't know, Hoser did an excellent HID retrofit on his 100 series, posted on that forum.
OK, here are the measurements. So if anyone finds a HID projector with these dimensions it can be installed without any modifications. No drilling, no cutting.
I was thinking of making a mold off my headlight glass & heating some 3/16" Lexan to make clear 'glass' - I have a set of R34 Skyline headlights sitting around to chop. You pushed that project further up my list.
I like the idea of that Nissan Part# B6553-89915 Headlamp Sealant too. I'll be looking for it.
Hid headlights don't pull any more current then any stock head light. What does happen is that a very high voltage is sent to the lamp from the ballast. This voltage could potentially damage insulation that is not rated for it, but it would not melt the copper wiring as a high current would do. The good thing is that the wiring from the ballast to the bulb almost always comes as a kit, and should be rated for the application, and shouldn't be a worry, unless somebody added some unrated wire.
Anyway, congratulation on a job well done, and once you go HID nothing else is good enough anymore. It is like a bad case of snobbinosytose.
Yes, however at start-up, they pull much current than halogens. I've seen many car fires due to electrical fault, a lot of them stock vehicles. I recommend not taking a shortcut.
Yes, however at start-up, they pull much current than halogens. I've seen many car fires due to electrical fault, a lot of them stock vehicles. I recommend not taking a shortcut. http://faqlight.carpassion.info/headlamp-harness.html
So I have another question. Why is that most cars have only 1 pair of HID headlights? Are these low beams only? Why not high beams too, or do they do both?
Low beams only, high beams require the Arc to start then get up to temp... WAY too much work for the bulbs and ballast assembly to handle for just a brief use. (most times) Besides Halogen high beams are pretty effective.
