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  • 1979 - 1995 (Fox, SN95.0, & 2.3L) -General/Talk-
  • 1994 - 1995 Specific Tech

PROJECT BLIND EM!

  • Thread starter Thread starter Bosko5.0
  • Start date Start date Oct 11, 2007
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Bosko5.0

Active Member
May 18, 2006
1,067
0
37
longwood, FL
Oct 11, 2007
#1
  • Oct 11, 2007
  • #1
Well since there are so many people wanting better lighting from there head lights, and the HID kits that sell for $150 aren't real hid kits.
Due to the fact that they create a glare and barely light up the road(with smoked headlights) though they are better then stock but for that much you can get cheaper bulbs to do the same.
Ive have had the poor lighting problem since I got my smoked lights.
I went from stock, then performence white bulbs, to "hid" bulbs, none really lit up the road enough to my liking and since I drive alot at night , I need the animals before I hit them; Then someone mentioned a while back about Using real HID lights So ive been searching and reading different forums So I kinda got the idea and have gotten far.

Heres some links to threads.

http://forums.stangnet.com/showthread.php?t=670834
http://forums.stangnet.com/showthread.php?t=612779
http://forum.e46fanatics.com/showthread.php?t=296547&highlight=xenon+diagram HERES SOME PICS

I bought them off ebay for $287 they are e46 hid lights the kit included: 2 ballast, 2 igniters, 2 ds2 bulbs(true HID bulbs), and 2 projector, and luckly no cut wires



Making the housing for the the lights was difficult at first, but with time it got better. First you wrap the projector in Aluminum foil twice, Then lay some fiber glass strips not too big or else it'll leave pockets of air and hole. But once you get the first layer all the way around you can put bigger pieces on. I put like 5-6 layers since I heard that fiberglass warps with heat so more shoulb be better.

Then I cut all the extra fiberglass off and cleaned it up some. then pryed it off the projector littleby little, Be very careful you don't break anything. It should look like this.



Then I neede to find a way to secure the projector to the housing and since the projector had 4 mounting holes on it I used them and poured some fiber glass into some take I layed out to make platforms( highlighted with black marker)




Once that was done I needed to clean up the front of the light and since I didn't use the bmw bezel that would of cost an extra $60-$90 I needed to make something so I wraped some tape around the front and put some tape over the projector lense so nothing sticks to it, I then placed a clyindrical object centered on the projector lense secured it the pured fiberglass in between the two and got this.

The black lines are from where I layed more fiberglass and filled in holes.

To get all the excess off I used my brothers nuematic angle grinder with a red scotchbrite and it cleaned it up nicely. Notice how I left a lip to hide the metal.


Heres where Iam right know.







I ran in to a snag when I could not locate the connector on the left.

I asked Ben if he had any lying around at work but he didn,t, So I asked neverclear over on e46fanatics.com and he came up with 2 part numbers for me.
PART # 61-13-8-365-348 PLUG HOUSING
PART # 61-13-0-006-665 CONTACT


So Yestterday went to pick them up at the bmw dealership right next to the Highway a couple of miles away. "LETS JUST SAY I GOT THERE QUICK" so i went in got the parts and lets just say they weren't cheap. if you don't believe me take a look at the invoice total ( those on the invoice are what I bought.).


So All I got left to do Is put some bondo on the housings sand smooth, practice cutting the test lights provided by vp6799 thanks man, then cut into My $200 headlights ,secure to housing, get it all wired up, work out the bugs. + all the little things.

So whachya think???
 

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Blackened302

Active Member
Jul 21, 2005
1,439
0
36
South TX
Oct 11, 2007
#2
  • Oct 11, 2007
  • #2
bad ass, man!!! been wanting to do this myself for some time, just never spent the cash on it.

subscribing!!
 

94-302-vert

Active Member
Aug 16, 2004
1,947
2
36
NE CT
Oct 11, 2007
#3
  • Oct 11, 2007
  • #3
Subscribing...

So keep us posted as to the total cost tally too... I would LOVE to do this and I have the time and expertise but jsut don't seem to know where to start...
 

ProKiller

Founding Member
Apr 26, 2002
3,064
15
78
PA
Oct 11, 2007
#4
  • Oct 11, 2007
  • #4
i haven't been around for a while so maybe you mentioned this else where, but where/how do you plan on mounting them on the car?
 

Zero Signal

Active Member
Feb 24, 2003
2,633
2
46
Tucson, AZ
Oct 11, 2007
#5
  • Oct 11, 2007
  • #5
Sounds like he's taking a Dremel or something to his headlights to retrofitting these in place. Are these HIDs the kind with the adjustable projection angle like on the Mazdas? That would kick butt.
 

Bosko5.0

Active Member
May 18, 2006
1,067
0
37
longwood, FL
Oct 11, 2007
#6
  • Oct 11, 2007
  • #6
Yes I will be mounting them in my stock headlights.

Total Cost:

Hid kit $287
Miscs. wire/ connector $32.63
fiber glass $20
bondo $12
wiring harness $75
---------------------------------------
Total so far $426.63
 
9

95oRANGEcRUSH

I dig fat chicks
Founding Member
Mar 27, 2001
631
0
16
Canton, Ohio
Oct 11, 2007
#7
  • Oct 11, 2007
  • #7
You dog! I knew you were doing a retrofit. This is awesome and looks like you're doing it properly. I'm sure it will turn out awesome.

On a side note, I checked with American Muscle.com and those projectors I linked to in the other thread can't be used with HIDs due to heat. However, I have been thinking of buying those headlights, pulling the projector out and puting Infinity FX35 projectors in. I just don't know the size of the halogen projectors in those headlights American Muscle sells.

Good luck on the rest of the retrofit!
 

m0l0

Member
Nov 20, 2005
178
0
17
Oct 12, 2007
#8
  • Oct 12, 2007
  • #8
Absolutely suscribing since i want to do this to my car, traveling on highway with stock gets boring after driving a HID car.
 

vp6799

New Member
Aug 15, 2006
124
0
0
Massachusetts
Oct 12, 2007
#9
  • Oct 12, 2007
  • #9
95oRANGEcRUSH said:
You dog! I knew you were doing a retrofit. This is awesome and looks like you're doing it properly. I'm sure it will turn out awesome.

On a side note, I checked with American Muscle.com and those projectors I linked to in the other thread can't be used with HIDs due to heat. However, I have been thinking of buying those headlights, pulling the projector out and puting Infinity FX35 projectors in. I just don't know the size of the halogen projectors in those headlights American Muscle sells.

Good luck on the rest of the retrofit!
Click to expand...

Don't hid's produce less heat??
 
9

95oRANGEcRUSH

I dig fat chicks
Founding Member
Mar 27, 2001
631
0
16
Canton, Ohio
Oct 12, 2007
#10
  • Oct 12, 2007
  • #10
vp6799 said:
Don't hid's produce less heat??
Click to expand...

Yes, but whoever emailed me back from American Muscle.com told me they can't be used with HIDs due to heat. Doesn't matter much; a halogen projector is not made for HIDs anyway internally. A HID setup requires the use of a HID projector, so I'm going to do my own retrofit in the next month or so.
 

vp6799

New Member
Aug 15, 2006
124
0
0
Massachusetts
Oct 14, 2007
#11
  • Oct 14, 2007
  • #11
95oRANGEcRUSH said:
Yes, but whoever emailed me back from American Muscle.com told me they can't be used with HIDs due to heat. Doesn't matter much; a halogen projector is not made for HIDs anyway internally. A HID setup requires the use of a HID projector, so I'm going to do my own retrofit in the next month or so.
Click to expand...

hmmm, that's wierd.. I always thought that the projector was the same.
 
T

turbogt

Member
May 1, 2003
723
16
19
Montana
Oct 14, 2007
#12
  • Oct 14, 2007
  • #12
impressive.. since I have a tinted windshield and smoked headlights, this is something I need to do.. I'm also pretty talented at fiberglass work..
 

The Green GT

No 13 year olds are safe around me.
10 Year Member
Jan 8, 2006
1,269
19
99
Louisiana
Oct 14, 2007
#13
  • Oct 14, 2007
  • #13
Do they make any of those projector housings with 9007 bulbs?
 

Bosko5.0

Active Member
May 18, 2006
1,067
0
37
longwood, FL
Nov 14, 2007
#14
  • Nov 14, 2007
  • #14
NO eric they don't make the projectors for for 9007 bulbs.

Finally I am allmost finished.

heres some pics of my $200 headlights destroyed to perfection .




I threw some rags in the headlight so that I don't damage the inside, with a file or debris from dremel.




Also covered the front with masking tape, since I kept putting the down lense first .




There is duston the lense.



And heres the mach up of the prorjector sitting in the housing.







And here a one eyed stang.



I will finish soldiering the wiring up to night (tomorning).
I ve just gots to cut into the other headlight like a 3 minute job, then file it to perfection 30 minute job
I am not done wiring the brights up since I am still waiting for some small parts to come in.


More to come.
 

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BlownFiveLiter

have car, will race....wait, it doesn't run
15 Year Member
Nov 29, 1999
3,133
18
108
Chicagoland
Nov 15, 2007
#15
  • Nov 15, 2007
  • #15
I'm gonna send you some headlights to do for me! Looking great! Once you're finished, I believe I'll add this to the Technical Thread sticky as a writeup on how to correctly do the HID swap.
 

94-302-vert

Active Member
Aug 16, 2004
1,947
2
36
NE CT
Nov 15, 2007
#16
  • Nov 15, 2007
  • #16
Looks absolutely Killer.... Now I want to know how much of a difference it makes in real life...
 

ProKiller

Founding Member
Apr 26, 2002
3,064
15
78
PA
Nov 15, 2007
#17
  • Nov 15, 2007
  • #17
very interesting.
 

Blackened302

Active Member
Jul 21, 2005
1,439
0
36
South TX
Nov 15, 2007
#18
  • Nov 15, 2007
  • #18
i'm green w/ envy...

nice job, man!!
 

Bosko5.0

Active Member
May 18, 2006
1,067
0
37
longwood, FL
Nov 16, 2007
#19
  • Nov 16, 2007
  • #19
Ive good good news and bad news .

Heres the bad news I can see 15ft infront of me now but not any further .
I rushed putting them in since it was like 60 degrees out and windy and I only had on t shirt and shorts. , and now my projectors face down to low . SO I have to cut them out and reseal them also one is tilted. there is also some jb weld that got into the light. and some of the reflective paint came off. . and still no brights.
Also I forgot to bring my camera.


And for the good news I have em in and they work.


Also on the way to work on them my alternator died. and then right before I left my battery died.
 

go-stang5.0

New Member
Jan 27, 2003
2,244
0
0
Glenview,Il
Nov 16, 2007
#20
  • Nov 16, 2007
  • #20
Bad luck Hopefully you get everything sorted out. I'm sure you can sell the prototype to one of these guys and make yourself a new cleaner setup now that you know what your doing....
 
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