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Old 08-24-2010, 06:36 PM   #1
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HID Projector Retrofit

EDIT 1
Need to roll props Yosh for his thread,
And then more props to Electron Man. Their threads were gold to me.

http://www.tacomaworld.com/forum/2nd...part-deux.html
and
http://www.tacomaworld.com/forum/2nd...-complete.html

So this is the cornerstone of a marathon of work and mods I have been doing on my truck. The mod is complete, but I need to get some more photos and finish aiming my lights. So less words, more Taco Pr0n.

So T/R/S sent me a box, it had some goodies in it.



Ballasts, Gatlin Shrouds, Phillis Bulbs, Morimoto Mini Ballasts



So the best part is that I used the Morimoto D2S Mini. The kit isn't on the sellers web site, however I emailed Matt, and he set me up. So the only thing I had to dremel was my shrouds. !

Here is the before shot. Really clouded. Low Tech Halogen. Dirty Grill (Jamoshi in the furture!)



So i dropped them in the preheated oven, 250 Deg F, 11 minutes, on a cardboard sheet. Turned the oven off. Getting them apart hurt my fingers. Next time I might do warmer/longer.

So the first thing I needed to do once they were open was remove the stock halogen shield. Flat head screwdriver to these tabs and some wiggling and they slid right out.



So the cool part about the Mini D2s Kit is that the projectors have this alignment washer and a notch to get the rotational alignment correct. It turned out pretty level for me. In the pic you can see the alignment ring, the place it sits in the back of the headlamp, and the notch on the projector assembly.



In order to get the high beam solenoid through the reflector w/o drilling, I disassembled the electrical connector, and poked it through a little pre-existing hole in the reflector bowl.

and


Modifying the Gatling Shrouds:
This was the crappy part of my weekend, lots of dust, so I didn't take pics. But I taped off the inner ring, took about 1/6.5 th of an inch off, and a pretty shoddy job of making notches for the projectors to fit. My rationale for modifying them soo much is that I did not want them casting shadows out wide and narrowing my beam pattern. Wither I accomplished this or not, who cares.

Next I used a Meguiars (Spelling?) kit to restore my lenses. If I were to do this again, I would do it while they are on the truck, and I would use the wet sanding technique. Maybe later.
Befores

Above is a comparison, only one is done. I also used clear silicon to affix the shrouds to the projectors, so here they are getting a chance to off-gas under my tonneau in the desert heat (it gets freaking hot under there). (Also Extang Trifecta Tonneau for sale cheap soon in Albuquerque area!)


As you can gander, huge difference in clarity. Meguiars is a simple one step restore. But its not perfect.


Removed my turn indicator covers. I have a chrome grill, so I did not BHLM , and I did leave the colored corners (legality concerns)


Alright, Update time.

I had to modify the boots to fit the D2S connector. You can see how much I trimmed there. This way the remaining fit is purity darn tight.



Below is the left side detail of how I mounted my ballasts. I used Velcro, industrial strength, mainly because I for got to drill mounting holes when the headlights were open. The wiring harness has a relay box that i mounted to the ballast its self using the ballast mounting bracket. I'm not happy about the velcro, but this worked out well for me.

and the right, I'm low on headlight fluid.


TRS sends you a wiring harness. the positive battery connector broke off. I put a larger one on and shrink wrapped it. Until I put in an aux fuse box, the headlamp fuse is captured by the battery bar there. Also I added some orange electrical tape (Go Broncos!) to makes sure nothing shorted.


You all asked for detail on my shroud butchering. Here is the best I can do. Just like the guys before me, I had to cut notches in the shrouds to get these to fit tighter. I did a poor job of that!

and


So here is the finished product: Meh, that pic sucked.
Ill get some night shots when I go to aim and give a finalz update.

Until then.
If I had to do it again I would:
Not break a bulb.
Use an AUX fuse box.
Be more careful yanking the headlamps open.
Not allow dust to settle in the headlamps after the oven closing treatment.
Wet Sand my lenses or source new headlamp. (Lots of risk in using my only pair)
Have the balls to do a full FXR Ballast Retro (well, maaayyybbeee).
Place angel eyes in my shrouds. That would be ill.


My Headlamps were recently removed from me by forces beyond my control.
I will be doing this mod again for my next Tacoma
My apologies for not getting night shots, but HID plant is a great resource ( I used it quite a bit

Here are some more shots from my build process that I found on my phone
I will most likely post more pics of the next build too.
Enjoy!

My Headlamps were recently removed from me by forces beyond my control.
I will be doing this mod again for my next Tacoma
My apologies for not getting night shots, but HID plant is a great resource ( I used it quite a bit

Here are some more shots from my build process that I found on my phone
I will most likely post more pics of the next build too.
Enjoy!

[FINAL EDIT]
Finished product


Before I put everything back together


How I taped off and modified for shroud modification




Again, I wont be getting night shots. My apologies.
(I actually went and tried 3 times, but needed a tripod and was being waaaaaay to anal about taking 3 pictures at the exact same exposure/iso/aperture/fstop so that the pictures were DIRECTLY comparable in a place that had showed the headlights well)

BUT! I will be doing this mod again in the summer with new headlamps, and probably some CCFL "angel eyes" to replace my DTRL's.

As a wrap, I HIGHLY RECOMMEND THIS TO EVERYONE. I recently drove a new 2011 Tacoma with stock headlamps and I felt blind.
-Chaco

PS - More info in Post 18 and some of my replies.
Those looking to Vacuum form check out this link:
http://hackaday.com/2010/12/02/vacuum-forming-at-home/
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Old 08-24-2010, 07:19 PM   #2
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looking good so far....can't wait to see the finished product...

I'm about to make me a retro-setup similar to yours...
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Old 08-24-2010, 07:33 PM   #4
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Looks good. How much did all the parts from TRS cost you?
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Old 08-24-2010, 07:41 PM   #5
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nice, appreciate the photos
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Old 08-24-2010, 07:57 PM   #6
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That kit is on the website...
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Old 08-24-2010, 08:13 PM   #7
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Sorry mates, did not take shroud pics. I will get closeups of the shrouds since they are on the truck now. I have also given the TRS some feedback on the kit. The wiring harness is a bit short.

One note is BE CAREFUL WITH THE BULBS. I broke one, and am buying a new one from TRS. The little posts on the back are fragile. I will snap some more pics in the afternoon tomorrow.
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Old 08-24-2010, 08:41 PM   #8
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Looks great thanks for all the pics and explanation as i will also be doing this soon. Cant wait to see the finished product
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Old 08-25-2010, 06:24 PM   #9
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Update Bump! TTT

Quote:
Originally Posted by chilidogrc View Post
Looks good. How much did all the parts from TRS cost you?
They got the kit on the website, I think 345 w/ the Phillips bulbs.

BTW TRS is pretty nice to deal with!
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Old 08-25-2010, 06:26 PM   #10
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trs is sick, got my retro there as well. i sorta have angel eyes on mine (see below pic) but i have to figure out how to mount them better, wheeling tends to make them fall off
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Old 08-25-2010, 06:46 PM   #11
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I think they would be ill inside the Gatling shrouds, kinda like a slotted ring of light.
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Old 08-25-2010, 08:03 PM   #12
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Quote:
Originally Posted by chacotaco View Post
If I had to do it again I would:
Wet Sand my lenses or source new headlamp. (Lots of risk in using my only pair)

Night shots next!!
pick up the 3m headlight restore kit at walmart...like $16. it comes w/ a drill attachment, 3 different grits of sandpaper for the attachment and some polishing compound. i got good sized rock chips out of my fogs w/ that kit, worked excellent!

now lets see those night shots!!
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Old 09-08-2010, 01:38 PM   #13
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great job

First of all, those look great OP! Congratulations.

I have been researching doing a HID retro while I save up the funds to purchase supplies. I had seen some awesome work on the forum with the FX-R retrofit and had convinced myself I was going to go that route. But now...seeing your awesome results...I might go the Morimoto Mini route. Minimal cutting of the reflector seems ideal and it is very close to a true plug-and-play.

I am not afraid to do the work required to retrofit the FX-R but I am having a hard time justifying the extra work. Could be because of my ignorance of the differences. So how happy are you with the Mini DS2 retro? Why do you mention using FX-R projector if you had to do it again? Anyone else want to chime in with their experience/expertise? I have emailed Matt at TRS and, like everyone has indicated, he is very nice and informative, but I wanted to get everyone here's insight as well.

Thanks in advance for any help.
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Old 09-09-2010, 08:13 AM   #14
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My mini D2S kit arrived at my office yesterday. I will be doing the install this weekend. I went with the Apollo shrouds just to be different. Looks like attaching the shroud to the projector is going to be the most time consuming part.
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Old 09-10-2010, 07:17 PM   #15
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Yeah Getting the shrouds snug is the hardest part. However do be careful yanking the headlamp apart, i broke some things off.

Also look into taking the reflector and painting it black, kinda like a reverse BHLM. Next time I open up my lights that is what I'm going to do.

Real life stuff has kept me from taking night shots, but I have been doing lots of night driving as I move from NM to CA for gradschool and decided to make it a week long camping trip. That and I am still tinkering with my aiming of the lights. But the Phillips bulbs kick ass!!
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Old 09-10-2010, 07:24 PM   #16
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Quote:
Originally Posted by S!LVERT4COM4 View Post
First of all, those look great OP! Congratulations.

I have been researching doing a HID retro while I save up the funds to purchase supplies. I had seen some awesome work on the forum with the FX-R retrofit and had convinced myself I was going to go that route. But now...seeing your awesome results...I might go the Morimoto Mini route. Minimal cutting of the reflector seems ideal and it is very close to a true plug-and-play.

I am not afraid to do the work required to retrofit the FX-R but I am having a hard time justifying the extra work. Could be because of my ignorance of the differences. So how happy are you with the Mini DS2 retro? Why do you mention using FX-R projector if you had to do it again? Anyone else want to chime in with their experience/expertise? I have emailed Matt at TRS and, like everyone has indicated, he is very nice and informative, but I wanted to get everyone here's insight as well.

Thanks in advance for any help.
Sorry Just saw this.
The beam pattern from the FX-R's is slightly better. And you have no rotational control of aiming. With a full retro you do, and you can rig it up so you have more aiming controll. I am finding these a bit diffucult to get where I want them, especiall with no flat parking lots near me, and my f***ing weak ass stock 05 rear leafs.

You see I bought my first Dremel to do this, so the lower cost and shorter less risky path was the only way I would do this. Remember that I did not have an extra pair of headlights to work on. This for me was a one weekend or bust mod.

I would seriously looking to leveling motors, as that will be my next reason for tearing the lamps out again. I wish I had independently rigged up leveling motors to all 4 adjustments. That way aiming would be stupid easy!!!!
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Old 09-10-2010, 07:26 PM   #17
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Quote:
Originally Posted by chacotaco View Post
I wish I had independently rigged up leveling motors to all 4 adjustments. That way aiming would be stupid easy!!!!
WAY overkill w/ 4 motors...all you need is 1...ask me how i know....
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Old 09-27-2010, 12:27 PM   #18
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Based on his great write up I got these projectors as well. I asked chacotaco some more questions via PM and he was very responsive and helpful. He made the great suggestion that we should get that useful information onto the page so here are some questions followed by his answers:

- Was it hard to get the first "ring" screwed in enough to get the second ring on when mounting the projector in the reflector? Any suggestions?
Quote:
Originally Posted by chacotaco
- Rings :
If i remember correctly, I had to de-burr the rings with a file in order to get them to tighten. This helped alot Then I grabbed with a vice grip and cranked away. But it wasn't terribly/plastic bending difficult, but firm. Do pay attention to the parts order of reassembly. I don't remember if I kept that silly black gasket, but the projectors have a soft plastic that mates well with the reflector bowl that you can compress.
(I recommend test giggling to see if you got them tight-enough.)
- I don't really know how these shrouds are supposed to fit, but they don't fit very easily. They don't reach the reflector bowl at all...do yours? Are they supposed to? I'd think if I could glue the shroud to the bowl it would add some support, but they sit about 3/4 inch away from the bowl. Any insight there?
Quote:
Originally Posted by chacotaco
Shrouds:
- I dremeled the snot outta the Gatling shrouds to get them to fit well. took alot of time and it still looks botched to me. I also removed some inner ring, and quite a bit of material to clear the corner housings. I would dremel, test-fit, dremel, ...... you get it. The inner ring modification was the best choice I made, but It also forced me to remove some slots on the back of the shroud as others did. I taped it off inside and then followed my tape line. Then to attach I put silicon just on the top of the PJ's themselves and slid the shrouds on. No slips yet!

I also removed material at the top of my shrouds to get them to sit back.I reallly wanted them to sit deep to make sure the lenses could spread light out as wide as possible.
- You mentioned using velcro because you didn't drill mounting holes while the headlights were open. How would you have mounted the ballasts if you had thought of it while they were open?
Quote:
Originally Posted by chacotaco
Mounting:
-I would have mounted them probably where I did, but with a screw. The clearance is good there (go check your on truck pair!) , I just don't know if the mechanical innards of the adjustment screws would play nice. If you do drill I suggest this :
Go look at the reference postings at the top of my page and see how those guys did it. Then also maybe JB Weld the screw in place coming out of the housing? Let that dry (since you are taking time), and then silicone seal if needed. That way you might avoid opening up the headlamps again if you need to replace a ballast because the screw/nut inside disappeared!
Great job chacotaco and thanks a ton.
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Old 09-29-2010, 07:58 PM   #19
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Looks good man. I am looking into doing this retro as well. Do you have any output pictures from this setup?
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