DIY 7" round HID Projector Retrofit on the cheap - JKowners.com : Jeep Wrangler JK Forum
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post #1 of 37 Old 06-09-2014, 12:07 PM Thread Starter
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Lightbulb DIY 7" round HID Projector Retrofit on the cheap

Ok so after doing a shit ton of reasearch online on the HID Projectors Retro's i decided that i was not going to pay Tom's price for a set of headlights, nor was i going to put up with shitty flickering LED's.

So came the time for the fun to begin.

Parts List:

7" Round H4 Projector Buckets - i used these http://www.ebay.ca/itm/121327788708 - you will only use the rear of this housing. $35
Jeep JK Stock Headlight Housing - you will only be using the front domed glass.
Red High Temp RTV Silicone - 5$
JB Weld High Heat Steel Stick (Putty) 6$
2.5" Projector Kit with your choice of shroud and Angel and Demon eyes. (I have a supplier for these and PM me if you need a price on these)


Butyl Rubber sealant rope. (window and door store just gave me a small piece for free)

2 big fuckin jugs of bleach.
Your choice of high heat paints
1 band aid (not for your finger)
Bag of Silica Gel Crystals (pet stores sell this shit as fancy cat litter)


Tools:
Needle Nose pliers
Rotary tool and bits. ie: dremmel
Household oven
Clean Plastic Wrap.
Painters tape.
Microfiber cloth
Large Rubbermaid Tub that will fit both lights sitting on the lens
Small spring loaded clamps

Let me Explain why you need the aftermarket rear of the housing with a photo.



Ok first things first get your H4 Housings out and pull the bulbs and everything off of them, toss or sell the bulbs, you will not use them
Preheat your oven to 225 and i mean preheat, don't just fucking put the lights in there before the cunt starts beeping.
Place a small folded towel on the oven rack and place the H4 Housings in the oven for 25-30 min
don't fucking open the oven until at least 25 min.
Remove one headlight and close the oven
Slowly pry the front glass off the housing, it should come off pretty easy once pre-heated, remove all glass and remaining glue.
Repeat for the other H4 Headlight.
Place the Stock JK Headlights in the oven and repeat the same procedure to remove the glass on both headlights.
Now remove the stupid fake bolted projector out of the H4 Housing by drilling the rivits from the backside, these holes will be filled with RTV at the end of the assembly.
If you hate the chrome and are paining your housings, fill a bucket with bleach and place the H4 Housing in the Bucket along with the shrouds.
Wait about 30-45 min and the chome will be stripped off.
Rinse well with clean water.
Using some painters tape, cover HID projector lens with Tape to protect it durring test fitting(trust me you will be fucking with it alot to make it fit perfect)
Also cover the openings to prevent any dust from entering the lens/ refelctor/cutoff shield area.
Grab your dremel and round out the inside lip just enough so the projector fits and you can fit the JK Lens on.


You may also need to dremel 1/16" around the sealing ring on the H4 Buckets and aound the JK Lens.



Rinse well the lens and projector, and let dry.
Cover the back of the projector with Plastic Wrap (3-4 layers), this is to prevent the Epoxy steel putty from sticking to the projector.


Quote:
Originally Posted by DMadole View Post
As previously mentioned, the key step in this process is saturating those whores in piss.
Quote:
Originally Posted by maunder View Post
I just gotta say.. When you're being butt hurt by your fudge packer minions.. how do you decide which one gets to pull the pony tail n who's left to cup the balls.. If there is any..

Last edited by Matti; 06-21-2015 at 10:25 AM.
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post #2 of 37 Old 06-09-2014, 12:07 PM Thread Starter
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Mix up a small amount of the putty.
You are going to use the putty to create a good fit on the inside and outside of housing.
Place the H4 Bracket onto the back and seal around the housing.
Install the lock washers and rubber washers from your Projector Kit and tighten the shit outta them until it lines up straight and your able to fit the JK glass on
It should look like this.


Repeat for the other light
Let the putty cure for a few hours.
Remove the projector from the housing.
Drill a small hole on the top 1/4 of the rear of the housing (this is for the vent)
You are now ready to paint your shrouds and housings what ever color you want.
Remove the tape from the projector carefully and clean the lens with a microfiber cloth.
Assemble Projector and and Shroud with angel eyes and demon eyes.
Test fit everything one more time after your paint has cured a few days. (Yes days not hours)
Test the angel eyes and demon eyes for proper function.


Remove the Projector one last time.
Place a small bead of RED Hight temp RTV on the backside where the projector will seat against the housing.
Re-assemble the Projector and Housing and Tighthen the Mounting nut. Making sure the Lens will still fit on and making sure all wires are fed through the back properly.
Cover the bulb opening with a small piece of tape to prevent dropping anything in and RTV THE SHIT out of the back of the housings(photo of the back of my light near the end)
Let cure 24 hrs.
Clean the inside of the lens and front of the projector well, this will be the last chance you get.
Prehead your oven again to 225
Place a strip of the Black Buytl Rubber rope tape around the edge of the headlights (you may need to roll or stretch the tape to shrink its diamater)
Place the lights lens down on a towel in the oven for 25min
Using your clamps(3 per light) clamp the headlight to the housing and let cool for an hour or so.
Seal the remaining holes (except the vent) with Red RTV, especially where the wires for the LEDS and High beam protrude out.
Take your band aid and cut off sticky parts, these will be used to cover the vents, this allows moisure to escape but keeps water out.
Take your silica gel and place it in the bottom of the large tupperware container wait a few min for the dust to settle (you dont want the dust falling in the bulb hole on the back of the light)
Place the container somewhere warm(i put it in the sun in the back yard)
Place the lights bulb side up sitting on the silica gel.
Place the lid on the tub and tape the seam.
Leave this sit in the sun for about 1 day or so, this is done beacuse the silica gel will adborb any mousire out of the air in the tub and the lights, you will not have any fogging issues, some skip this step but thats your choice.

Install Bulbs and Lights in Jeep and admire.



Here is a few pics of where i mounted my ballasts, relay and Canbus decoders.






Quote:
Originally Posted by DMadole View Post
As previously mentioned, the key step in this process is saturating those whores in piss.
Quote:
Originally Posted by maunder View Post
I just gotta say.. When you're being butt hurt by your fudge packer minions.. how do you decide which one gets to pull the pony tail n who's left to cup the balls.. If there is any..

Last edited by Matti; 06-09-2014 at 12:15 PM.
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post #3 of 37 Old 06-09-2014, 01:01 PM
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thank you for this, getting ready to do this exact setup. who did you use for the projectors, shrouds, and halos? you can pm me if you want
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post #4 of 37 Old 06-09-2014, 01:14 PM
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Nice write-up, man! Lots of work, though. And probably not much cheaper than what I paid to have mine built. One of my favorite upgrades so far. Think I paid right at $470 to have Tom @ HID Projectors build mine. No angle/demon eyes, though. Just a CCFL halo behind the shroud to create a city light effect.

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post #5 of 37 Old 06-10-2014, 01:14 PM Thread Starter
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FYI the prices i listed were in Canadian dollars

Quote:
Originally Posted by DMadole View Post
As previously mentioned, the key step in this process is saturating those whores in piss.
Quote:
Originally Posted by maunder View Post
I just gotta say.. When you're being butt hurt by your fudge packer minions.. how do you decide which one gets to pull the pony tail n who's left to cup the balls.. If there is any..
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post #6 of 37 Old 06-10-2014, 01:52 PM
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Quote:
Originally Posted by Matti View Post
FYI the prices i listed were in Canadian dollars
Must've missed that part.

Still, though.....great work!

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post #7 of 37 Old 06-10-2014, 02:19 PM Thread Starter
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No that was my bad, us Canucks making assumptions again

Quote:
Originally Posted by DMadole View Post
As previously mentioned, the key step in this process is saturating those whores in piss.
Quote:
Originally Posted by maunder View Post
I just gotta say.. When you're being butt hurt by your fudge packer minions.. how do you decide which one gets to pull the pony tail n who's left to cup the balls.. If there is any..
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post #8 of 37 Old 06-18-2014, 07:19 AM Thread Starter
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Another local member is taking this on, will have some more pics soon.

Quote:
Originally Posted by DMadole View Post
As previously mentioned, the key step in this process is saturating those whores in piss.
Quote:
Originally Posted by maunder View Post
I just gotta say.. When you're being butt hurt by your fudge packer minions.. how do you decide which one gets to pull the pony tail n who's left to cup the balls.. If there is any..
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post #9 of 37 Old 06-18-2014, 08:37 AM
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Awesome job! I'll be keeping an eye on this
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post #10 of 37 Old 06-18-2014, 02:02 PM
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Quote:
Originally Posted by Matti View Post
No that was my bad, us Canucks making assumptions again
So youa re saying those of us in the US can build these for about $35.


Jon

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post #11 of 37 Old 06-19-2014, 10:32 AM Thread Starter
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hahaha probably

Quote:
Originally Posted by DMadole View Post
As previously mentioned, the key step in this process is saturating those whores in piss.
Quote:
Originally Posted by maunder View Post
I just gotta say.. When you're being butt hurt by your fudge packer minions.. how do you decide which one gets to pull the pony tail n who's left to cup the balls.. If there is any..
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post #12 of 37 Old 08-14-2014, 05:58 AM Thread Starter
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Another set a friend just finished


Quote:
Originally Posted by DMadole View Post
As previously mentioned, the key step in this process is saturating those whores in piss.
Quote:
Originally Posted by maunder View Post
I just gotta say.. When you're being butt hurt by your fudge packer minions.. how do you decide which one gets to pull the pony tail n who's left to cup the balls.. If there is any..
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post #13 of 37 Old 08-14-2014, 09:25 PM
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Just be careful with those generic knockoff projectors out there. If you're going to do the work to retrofit some projectors, might as well get the full benefit.
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post #14 of 37 Old 08-14-2014, 09:39 PM Thread Starter
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Very good point, that why I buy mine from toms supplier.

Quote:
Originally Posted by DMadole View Post
As previously mentioned, the key step in this process is saturating those whores in piss.
Quote:
Originally Posted by maunder View Post
I just gotta say.. When you're being butt hurt by your fudge packer minions.. how do you decide which one gets to pull the pony tail n who's left to cup the balls.. If there is any..
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post #15 of 37 Old 08-14-2014, 09:42 PM
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I have the D2S 3.0 and the output is very impressive!

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post #16 of 37 Old 08-14-2014, 10:07 PM
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Man those are some seriously sweet lights. I need to find someone who wants to tackle something like this (I'm no way comfortable trying something like this).
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post #17 of 37 Old 08-14-2014, 10:14 PM
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silly question. why do almost all projector lights have that little zig zag in the middle? Im guessing it has to do with the alignment, but it always bugs the crap outta me when I see it.

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post #18 of 37 Old 08-14-2014, 11:16 PM
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It's for oncoming traffic, the beam is lower on the left hand side to keep from blinding drivers in the opposite lane.

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Some folks are fine with being screwed over, perhaps finding confrontation to be more stressful than just living with whatever the problem is. These are excellent consumers, manufactured to the finest specifications.
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Quote:
Originally Posted by Matti View Post
Another set a friend just finished

How much does your friend want to sell these for...


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and yet... canada still sucks worse

we'd make fun of your prime minister if we could... unfortunately nobody's ever heard of him!
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post #20 of 37 Old 08-15-2014, 10:16 PM
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Quote:
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How much does your friend want to sell these for...
Buy the parts and i'll retrofit a set for you. Lazy bastard!

Quote:
Originally Posted by braindead0 View Post
Some folks are fine with being screwed over, perhaps finding confrontation to be more stressful than just living with whatever the problem is. These are excellent consumers, manufactured to the finest specifications.
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post #21 of 37 Old 08-16-2014, 08:45 AM
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Quote:
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Buy the parts and i'll retrofit a set for you. Lazy bastard!
Haha! Yesssss!


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and yet... canada still sucks worse

we'd make fun of your prime minister if we could... unfortunately nobody's ever heard of him!
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post #22 of 37 Old 09-02-2014, 09:57 AM
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These look pretty good. Got to look into local laws and see if it's legal in Texas.


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post #23 of 37 Old 09-02-2014, 09:58 AM Thread Starter
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Just don't turn on the led's on public roads and you will be fine.

Quote:
Originally Posted by DMadole View Post
As previously mentioned, the key step in this process is saturating those whores in piss.
Quote:
Originally Posted by maunder View Post
I just gotta say.. When you're being butt hurt by your fudge packer minions.. how do you decide which one gets to pull the pony tail n who's left to cup the balls.. If there is any..
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post #24 of 37 Old 09-02-2014, 12:26 PM
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The halo's? Don't run them on public roads. I was thinking there might be an issue with the brightness?


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"Government is not the solution, it is the problem."
"We are never defeated unless we give up on GOD."
"Freedom is never more than one generation away from extinction. We didn't pass it to our children in the bloodstream. It must be protected, and handed on for them to do the same."
Ronald Reagan
Life is 10 percent what happens to you and 90 percent how you respond.
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post #25 of 37 Old 09-02-2014, 12:33 PM Thread Starter
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A properly aligned projector HID light is much safer than anything else.

The alignment allows the clean cut off to be below peoples mirrors and eyes.

I have never been flashed at night

Quote:
Originally Posted by DMadole View Post
As previously mentioned, the key step in this process is saturating those whores in piss.
Quote:
Originally Posted by maunder View Post
I just gotta say.. When you're being butt hurt by your fudge packer minions.. how do you decide which one gets to pull the pony tail n who's left to cup the balls.. If there is any..
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