D.I.Y morimoto bi-exnon retro-fit headlights

I finally finished my head lights. my retofit was harder because my ARB bumper blocks the grille.
so i had remove the bumper to do this so it added a lot of time.
I bought the following from
https://www.theretrofitsource.com/headlight-conversion-kits/toyota/tacoma/2002
Bi-Xenon: Morimoto Mini D2S Stage III CRK-D2S 1
THE KIT PRICE $407.00
BELOW LIST IS EACH ITEMIZED AND PRICED ITEM(S)!!!
Bi-Xenon Projectors
2 x Bi-Xenon: Morimoto Mini D2S 5.0: (Round Lens/LHD) $145.00 PR56
Shroud Preference
1 x Turbine (Set) $25.00 S340
HID Ballasts
2 x 35w / D2S: Morimoto XB Ballast $100.00 BL12
D2S HID Bulbs
2 x D2S: XB35 5500K (35W) $30.00 B650
Wire Harness
1 x MotoControl Bi-Xenon: H4/9003 $25.00 H60
Optional Housing Sealant
1 x Black: RetroRubber $12.00 A330
Optional LED Halos
2 x 110mm: Profile Pivot Ring w/ Driver (Switchback) $70.00 LED260
Demon Eyes: Profile Pixel OneColor B-1C-M-LED764-LED141 1 $31.00
Demon Eyes (Color)
2 x Demon Eye: Profile OneColor (Green) $25.00 LED764
OPTIONAL MOUNTING BRACKETS
2 x Demon Eye Bracket - Mini D2S 4.0 (w/ FGL) $6.00

1. I made a makeshift BOX oven using a cardboard tube and a large cardboard box and 1 small cardboard box inside to hold the housing up. and my old harbor freight heat gun set at 550f and a strip of aluminum tape to hold it in place for 10-15 mins. then you can open the lens pretty easy. my thermohawk laser thermometer says 175-180f and that is enough to open the lights.

 

2. I stripped all the chrome off the reflector using eagle one never dull wadding chrome polish.......If its not real chrome this will eat it off while you wipe it. this is after just a minute of wiping. I stripped them down completely. then you need to make the rear bulb mounting hole a tiny bit bigger as to get the lock ring to spin and tighten down correctly later. I did not take a picture of this as it was a dusty mess!!! Also you need to remove the tiny part that used to hold the bulb lock down spring into place. just snap it off or dremel it off. This way you have just enough room for all the wires to pass behind the projectors nicely and out that square hole.

 

3. cleaned up all the dust masked the edges where the black glue is in the channels only and spray paint the entire reflector and edges. make sure you strip the chrome from the outer edges very well. you don't want to see that after all this work. after the paint was dry i installed the projectors and demon eyes. I like one color Green so i didnt buy a RGBW controller or switchable halos.

 

4. I installed the switchback (white-amber) halos with the mounting rings into the turbine shrouds with tiny plastic specific screw- metal screw for plastic has course fast threads. pulled all the wires through the square hole. and i resealed with the retro rubber. make sure you cut off about 5-6" of the retro rubber off the huge F'n roll and stretch it as you push it back into the channel. if you use to much it will be a real PIA to squeeze the housing and lens back together. I have quick clamps so i used them and a little body weight to seal them up (after you put them back into the oven) and then repeat the process of baking them to soften the rubber sealant then press them back together fully.

 

5. wiring the h4 harness first.
i mounted it next to the battery as the wiring harness doesn't have more than 6" of slack and 1 side is longer to go to the passenger side only and vise versa. There is a ground bolt on each side if the fenders. you cant quite see it but that gold box and the left headlight ground from the harness are hooked up here. perfect spot on both side because they are existing grounds already. so on the passenger side use the same ground. The ballast are connected to the top via a nut-sert after using a push punch to mark the holes holding the ballast against the fender as a your guide to punch the drill starting points. then i used 2 small nut-serts to attach the ballast's to the fenders.then hook up all the ballast connections to the lights. the kit came with the rubber seals for another model i may cut them off. My stock headligh boots were pretty crumbly so i have some new on order. Thats why in the next step i made Hardwired connectors for the power leads.

 

6. wiring the demon eyes and halos into the parking corner lights and turn signals.
pull the corner lights out unplug at the harness- do not take the bulb out and measure about 2-3" below connector coming to corner light and cut it off. dont worry You can solder right? Then i had laying around some male and female cctv plug ends for my home security system builds. use a female connector and solder the connector wires of your choice to factoy wires and then join the factory connector plug back inline with the new connector coming off the side at 90 degrees. I soldered every connection and used shrink wrap to seal it all up. Im out of wire loom for a couple days until Amazon gets here with more so dont laugh at the baggy tape its holding an length of wire in a loop as i didnt want to shorten the wire and until the loom gets here i taped it up.
I took the demon eye wires. red and black and soldered them to the led exciter prisms. as follows the (RED wire from the demon eye power needs to be connected to the (white wire on the exciter black box and then those 2 wires into the the connector of your choice's RED wire. then the black wire from connector to black wire from exciter black box. on the other side of the connector the (male side of your connector of choice) wire the GREEN wire from the trucks wiring to RED wire of your connector. Then the negative wire of your connector to the white wire with the black stripe there is only 2 wires but in case. then the orange wire from the exciter black box goes down and either splices or you hard wire it to the RED power wire on the turn signal. This way if you flip on your parking lights your corner lights and you halos and you demons eyes will all come on at once. and if you hit you keyless entry all these lights will now flash together.

 

Now i haven't taken the truck to work yet to do the headlight restoraton kit i have so. the outsides look shitty but they wont tomorrow once i use my kit. But here is the end results for day time night pics coming soon.
I will get pics of the halos blinking. I cannot upload the 34 second video file i have.

 

Wow really nice this will be my next mod!

 

here are the night pics. Now keep in mind i have dark crystal tinted lenses and as you see it does affect the light output but i love these housings and have had them for many years and many HID kits through them so i was prepared for less light due to this fact. Hard to see in the pics but the turn signals are awesome when the halo and bumper turnsignal both blink together.

 

Here is a great shot of the halo on and the demon eye on with park lights on and no headlight. In turn signal switch back mode. I paused the video and took a screenshot.

 

You need to lower the passenger side headlight to be even. It should be like this _/ _/ both of the steps should be even with each other

 

Did you have to cut anything to make the projector fit? Doesn’t look like it.

 

no i didn't have to cut but you do need to clearance the back. Also i didn't have time to adjust the lights that's coming up next on sunday so i am addressing the light cut offs to be level
. I just did the outer lens restoration yesterday.

 

@Rldanie
Same year,

Some ideas for you

 

I have all my parts, I just need to take a "vacation" from WFH and do this. too cold from Black Friday until (hell even now, it snowed on Friday) current and keeping the job is more important that fitting lights