Another Mini D2S Retrofit from TRS

Using the how to guides here, I just completed a Mini D2S Retrofit and black headlight mod, using hardware purchased off of TRS. The guides available here and at HIDplanet make it VERY easy for a DIYer. I thought I'd just add my $0.02 to some of the issues/problems I ran into for the next guy.

1st step: remove headlight assemblies. The #1 biggest issue here is getting one particular bolt off -- it's lateral attached to the fender -- a real PITA. The only way I could do it was to take off my bumper. I didn't bother putting that 1 bolt back on when I re-installed the headlights. I just put some black RTV silicone gasket maker on the end.

 

That 1 stubborn bolt is located at the red arrow.

 

Step 2 is to remove all the bulbs and rubber parts. That's well described else where. Once that's done . . . time to bake. Baking the headlights was the part I was most concerned about, but it turned out to be the least problematic part of the whole project. Just use some wood or cardboard to place on the oven rack . . . only one headlight at a time fit. I used 285 degrees for 10 minutes. I've heard different times and temperatures from different people, but this worked for me. It wasn't too difficult to separate the halves usine a large flat head screw driver and elbow grease. When done . . . they're separate like this.

 

I removed the halogen bulb shield with a dremel. Too easy. FYI. . . if you're installing CCFL angel eyes on the shrouds, I think I found the best place to run the wires for the CCFL angel eyes. Using a dremel, enlarge the area shown in red to look like the picture. Then, the white connector to the CCFL angel eyes will fit through this hole. While on the topic of CCFL angel eyes . . . TRS recommends 100mm for the Gatlin Gun shroud, but once installed they don't line up exactly with the light openings . . . I'd recommend 90mm ones.

 

I painted the shrouds a metallic black to look like this:

 

I did the black headlight mod in the same color.

 

Here is the color:

 

Once aligned: Low beams:

 

High beams:

 

Oh one more thing . . . . the electrical harness. TRS told me that the orange/black connector went to the ballast and the blue/black connector went to the high-beam solenoid. Nope . . . other way around for me. Blue/black went to ballast. Orange/black went to solenoid.

 

I am dangerously close to ordering this kit from TRS. Can you show some pics of the finished headlight with the halos. Do you wire the halos up separately and run a switch to the cab, or what?

I like your idea of painting the shrouds. I've been thinking of doing this and the bhlm at the same time, but using some black chrome wheel paint i found. I think that would look absolutely sick with my Pyrite Taco.

 

The 2nd picture is actually the completed headlight assembly. As far as pictures of the lights on. . . I will try to post some pics. But pictures of lit headlights are difficult to make look like what they look like in person. As far as wiring the halos, you can wire them to turn on however you like. The halos have white wire running to a small inverter, then the inverter has a black and red wire that you run to ground and 12 V DC source respectively. You can wire them to turn on with the parking lights, by tapping into the parking light 12V positive and ground. Or you can run a switch to your cab if you want to.

I will say this about the halos. B/c I left the reflector bowl unpainted, the light coming from the back of the halos, also reflects off the reflector bowl, so there is light coming out the gatlin gun shroud slits and also a "glow" around the reflector bowl. If you don't like the "glow" then I would paint the reflector bowl a solid color -- black or whatever you like.

 

picture of just the angel eyes lit . . . . tough to see what it really looks like in person, b/c photographs of lit headlights never look like the real thing.

 

Picture of headlights lit up:

 

picture of both angel eyes lit:

 

what type of shroud did you use? Thanks

 

Gatlin Gun

 

Looks good man. How much did the total project cost ya?

 

1 x Bi-xenon Morimoto Mini Stage III Kit (D2S) (MiniD2SIII) = $375.00
Bulbs New Philips 85122+ D2S
Ballasts 1) Morimoto 3Five 35w
Shrouds Gatling Gun
Wire Harness Relay: H4/9003
Projectors LHD (North American Standard)
Re-sealing Glue Yes please
CCFL Angel Eyes Yes
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Sub-Total: $375.00
USPS Priority Mail: $16.74
Coupon TRS34: -$16.74
Total: $375.00

Then like, $2.00 for spray paint.

 

Great write up! +rep for that.

The truck looks great too, I would love to see a daytime pic.