3rd Gen BHLM + Retrofit Projector

OBJECTIVES:
-Swap the OEM projector with upgraded Bi-xenon (Now I will have 4 HighBeams)
-Black out all chrome

THE GOODS:

From left;
-H11 to H11/9006. This will PnP and split the highbeam signal over to the new Bi-Xenon
-D2S Bulbs 6k
-D2S XB35 ballast
-RX-350 NON-AFS projectors. (STi-R clear lens, and tuned)
-Re-sealing rubber
-HD relay

First:
pull grill/bumper off to access the side headlight screws;


mask off and throw em' in the oven. First try: 240deg @ 18min. Sealant was still hard, so back in at 260deg @ 10min.


Started to break loose, but needed 1 more bake and finally got it off;

The turn signal is in a separate bucket. Low/high beam are together in the same one;


They look very similar but the light output is night and day


Thankfully, the new RX350 projectors share the same bolt pattern as the OEM ones. Only 1 problem- highbeam solenoid makes contact with the housing.


So I took a dremel and cut a notch(all red area)


Will update tomorrow with the painting and re-assembly.

In the meantime--Here are a few light output shots;(~50yards)
OEM low beams;

Single RX;

 

Finallly!

 

Subbed

 

Very nice. Any collateral damage to the housings? Let me know if you need any tips patching them up - I'm an expert by now!

 

^ Surprisingly, not much. Few corners got bent when prying it open, but hit it with a heat gun and its back to normal. Getting the permaseal out was EXHAUSTING. I tried the heat gun, but it seems that it has a higher melting point then the plastic. Just used a flathead screwdriver and some elbow grease and scraped it out.
Headlight housing cleaned up and ready for some retro-rubber;


Wanted the orange side markers just a LITTLE darker. 1 quick mist spray of lens tint(From the inside!) worked perfect


Got some painting done today. I wanted the look of the TRD PRO lights, which leaves a chrome ring around the projector. Masked off;


lightly scuffed with scotch brite and sprayed with Krylon MAXX matte black paint;


All parts layed out. Ready to re-assemble

 

Can't wait to see them assembled and installed. I toyed with the idea of the chrome ring - maybe I'll be inspire to do it on my next set.

 

WOW these light look sexy! Perfect balance of black and chrome IMO. (at least the PRO got something right!)
All assembled, will seal them and install tomorrow.

 

I agree. Looks great. Good job man!

 

Thanks guys. Also, I painted the cutoff shield inside the projector with high temp black paint. This gives the projector a darker look when looking at it from the front.

 

Those look pretty bitchin.

 

Re-sealed. Retrorubber in the channel then back in the oven @ 230 for 10min. 10 Spring clamps per light to hold pressure as it cools.
I ended up flipping the stock rubber gasket around and cutting a notch to fit the igniters. Then a zip tie hold it tight;


Toyota knew I was doing this, so they provided me a perfect access cap on the bottom This is where I can stash my silica packs for extra moisture insurance;


Back on! I'll get beam shots when it gets dark

 

Very very nice! Thank you for documenting the process. Some day I hope to do mine!

 

No prob. Couldn't find any solid info on this yet swap yet so glad to help others in the endeavor.

planning on some baja designs led pods

 

That looks really good. Do you think if i just did the BHLM i could do it in a couple hours?

 

Looks great!!

 

This was much easier then my 2nd gen retro.(had to grind, cut off parts, mount a universal projector, etc)
I knew going in the projector would be the same bolt pattern, so that was nice. But the permaseal made up for it

MAYBE
I did this over a 3 day period working ~ 3hours at a time. But it takes some time to bake them, pull apart.. then paint. and prep the housings(remove all glue) and re-seal them. then re-assemble the whole front end.
Any questions just let me know!