Struggling with my Retrofit

First off I'll say I drive a 2005 Taco. I ordered the Mini D2S Retro w/ Gatling Gun shrouds through the group buy. I have everything painted and was installing the projectors today when I ran into trouble.

I cranked the locking nut down as far as possible on the back of the projector. However when I go to install the bulb it doesn't far enough back for me to be able to fully connect it to the ballast. Am I doing something wrong here? Any help is much appreciated!!!! Attaching pictures below for reference.

 

hmm which rubber grommets did u use on the projector? last I remember theres supposed to be rubber spacer things. maybe use a smaller one?

 

The only spacer that came with my kit is that big clear one on the back of the projector. Theres nothing below the locking nut in the second picture. Also I moved that clear one down a little on the projector to even get as much clearance as I currently have. Before I didnt even have enough clearance to get that backing nut that holds the light in

 

Also I am I am using Depo headlights not original OEM. Could that be a problem?

 

Anyone? Bueller?

 

You aren't doing anything wrong except missing a step. You have to grind the backing down. until its literally just thick enough to hold the alignment ring in place.

Hard to see but here it is:

 

I think I understand. So I need to remove the reflector bowl from the housing and grind down the backing so it barely still holds that 3 pronged metal washer on the bottom?

 

Set the alignment ring right in there and take a dremel to it until it's all flush with the ring

You're cutting all of it down like 1/4"

 

LOL I should've just gone FX-R. Thanks for the help sir!

 

Honestly the Mini is 90% as good as the FXR and a bit easier to install on the 2005-2011

 

Sorry for the late reply, been without internet for a few days. I had the same problem but instead of grinding down the plastic, I decided to grind down the nut instead.

After doing this, the nut will fit within the raised plastic of the housing and sit flush with the tabbed washer.

 

Thanks for all the help! Grinding the back of the headlight was much easier than I though it would be.

 

Did that fix your issue?

 

Sure did!

 

what did you use to grind it down? if dremel what attachement? I did my retro yesterday, and have this EXACT same issue.

I am waiting for the tech guy at TRS to call me back with help. They have been great but wanted to talk with him.

Please let me know!

 

Yes I used a dremel. It was actually much easier than I expected. The backing of the headlight underneath that locking nut in my original pictures is actually just a very hard plastic so it was very easy to grind down. I just used that cone shaped attachment on the dremel. Just remember not to grind it down to much because that 3 pronged washer still needs to fit securely in there. I took almost 1/2 inch off mine tho and it worked out perfectly

 

All you need is the drum sander attachment

 

And like you, I do not want to have to take the bowl apart. Did you have to take the bowl out of the housing to do this?

 

No I left it all together. You can access the back plastic part easily still with it all attached