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HID Retrofit 2009 Tacoma Extended Cab

Discussion in 'Lighting' started by 95SLE, Mar 27, 2012.

  1. Mar 27, 2012 at 6:47 PM
    #1
    95SLE

    95SLE [OP] Starting to get cold outside

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    Custom XM Install, Window Tint, Intermittant Wiper Install, AVS Bug Deflector, Bed Mat, TRS FX-R retrofits, CIBIE fog and spot lamps, PIAA 510 lamps, Acess LE cover, Weathertech Digital floorr mats, LED interior lighting, Pioneer AVH-2300BT HU, Boston Acoustics speakers, JL Audio Amp, shorty antenna, leather wrap steering wheel cover, Viper security system.
    I finally had the time to devote 100% of my attention to theHID retrofit for my Tacoma. Iparticipated in the group buy last November/December. I purchased the FX-R Stage IV kit with CCFL rings, Gatling Gunshrouds, and extra sealing compound.

    Link to TRS

    http://www.theretrofitsource.com/product_info.php?cPath=24&products_id=205
    This is what the kit looks like when removed from the shipping box.

    DSC_0007_b4dc266895feb92ce0ad9fb55ce2f09f9f1c3027.jpg



    I also purchased a set of OEM headlights from another member. Thanks Dave!

    DSC_0008_eae305fc937e87efdea68e5cbca1d59d3db2233f.jpg



    My workbench set up for the retrofit.

    DSC_0009_15df19280d058f377c167ac7c9ba5f0dbdbe0c50.jpg



    First up was to disassemble the headlamps. I preheated the oven to 255 degrees then put the headlamps in the oven, turned off the heat and let then sit in there for 7minutes. One of the headlamps needed two cycles to finally be able to pull them apart.

    DSC_0012_c1995884cc479db4fc02d7ab90cdb09cbcadfffa.jpg

    DSC_0011_af52d3a699b237bb7ef58113de25258ff85e186d.jpg



    Before removing the Halogen bulb clamp the reflector to as tationary object, in my case a rolling cart. I marked the reflector and the position on the cart as well as theposition of the cart wheels on the floor. I then fired up the low beam and marked the cutoff pattern on the garage wall. You will need the markings on the wall onceyou install the HID projectors in the reflector.

    I next used a 2 3/4 in bimetal hole saw to cut a hole in theback of the reflector bowl.



    I removed the circled protrusions with a hack saw. This enabled the hole saw to fit flushagainst the reflector bowl.

    DSC_0054A_f4894abc3832408e3a0169d03308e673d0855a63.jpg

    DSC_0056A_63035f9ce324ce711409aa3b0993dafb3da05b15.jpg

    DSC_0057_684a1d35b282d468f616ba169cbb49170097ae19.jpg

    Finished cut. You cansee that I cut a notch at the bottom of the bowl to allow the solenoid toprotrude out the back and allow the wires to go out the back. You need to make the notch larger than thisto allow the CCFL connector to be routed through the hole. I found out the hard way that it was notlarge enough.

    DSC_0058_ccabf4a8e8e3df856cf3b7df251e17c7d4e37864.jpg

    Next up I positioned the projector in the reflector bowl, markedthe screw hole locations, drilled the holes and mounted the projector. In this pic the projector is nor 100%horizontal so I need to tweak it to have it horizontal in the bowl.

    DSC_0059_08d008741bbe89f4c1ac1c2824e35f865774149a.jpg

    Once you are satisfied that the position is correct then youcan light up the projector and see if the cut off line are the same as the onefor the Halogen bulbs. At this point youcan start to assemble the reflector. Iused a red hi temp sealant to fill the gaps where the bowl and projectormeet. I also did the same where thescrews came through the reflector bowl.

    DSC_00072_7d29304db8c7ff80024acee9dd056d1a842d7acf.jpg

    I let this dry overnight before proceeding. Next I used hot glue to secure the CCFL ringto the inside of the shroud.

    DSC_0067_6d49be3c747296b631c0e91bec6b3a2de14b467c.jpg

    I put sealant on the inside of the concentric ring to sealit to the shroud.

    DSC_0065_814ed0cd592286bf0aa9c89b99e2700982001681.jpg

    DSC_0066_1b45bde9a44a9a023cba8a8bd2131e64eb35ac33.jpg

    I then ran a bead of sealant at the base of the projectorand installed the shroud.

    DSC_0068_7cd21296421e47c849deb0b6e3383d4f14c4421c.jpg

    DSC_0069_36fbe735b6751b691f83f0c2ba4fd3aba9bdd820.jpg

    Headlights sealed up.

    DSC_0070_f944115ccd6f023b7b1ccf9c1e188d4a4b8ed41f.jpg

    Two pics of the ballast and CCFL ballast mounted on the sideof the headlamps.

    DSC_0015_8d4686d046df6c6347bc9053ac7a7f7c431f8ef0.jpg

    DSC_0014_3d214bc08b6a3445a9c9c1e04d49977cf0922e7a.jpg

    Headlights mounted in the grill

    DSC_0012A_20ae23e232ea32c4c9c5529a50f332489f94a6af.jpg

    CCFL lit up in the daytime

    DSC_0013A_304ac2681c23e2c8480b2d751f2423e41a7afe1f.jpg

    Painting the trim ring was a separate process that took 3 days due to my letting each phase of the paint dry for an entire gay before moving on. I am very happy with the colormatch to the BSP on my Tacoma

    Headlight trim taped up and ready to primer. I removed the lenses prior to the masking.

    DSC_0071_e4f3274377e83402845f17344b96778e25586b82.jpg

    Two coats of adhesion promoter and 3 coats of flexibleprimer applied.

    DSC_0072_5d6bcfd442bc00af532341b61704c8879fa0db3d.jpg

    The trim painted up with 4 coats of BSP and 4 coats of clearcoat.

    DSC_0073_c7fb7ab52a1dc96be18347d9ad43b3333d9d65bc.jpg

    The reflector bowls with projectors mounted back in theheadlight housing.

    DSC_0074_9cc5d5944af0e3ff1c7f1995864942f2b42b8448.jpg

    Inner trim ring painted BSP

    DSC_00102_c66e8550eb3c1b6dd55bead0f2c41b74993bbbe6.jpg

    Test fit trim ring into housing

    DSC_00092_6377cdc2f1ed6b5da4842ea6f951360d1e3f16e9.jpg

    Trim rings secured to clear plastic headlight cover.

    DSC_00112_210237dede22ae5d1da20810e3d4f649a2c4c557.jpg



    Final results in the garage

    Tacoma_1_4ced22da0b5bd8b94f2737c548759f0ed5fce645.jpg



    I will get some better pics tomorrow in the daylight. I will also post some illumination pics onceI have the headlights adjusted properly. This may take a few days.
     
  2. Mar 27, 2012 at 6:48 PM
    #2
    95SLE

    95SLE [OP] Starting to get cold outside

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    I finally was able to do a decent alignment.

    DSC_0021_36138c5f763b4b085b4b7cd33bf1935ba93782cf.jpg

    DSC_0022_a5398c7da8d39a56312a3b19030b291cb2746c52.jpg

    DSC_0023_bdcea45f78e112fe917662cd29a28c4dbe0f3bef.jpg

    DSC_0024_79f7d87d212bf1006f18adfba952e51c4e755e3a.jpg

    A few lighting pics.

    DSC_0025A_f932231ceffb883a4f06c4b2c6760b65ada607e3.jpg

    DSC_0026A_4f8f9e51a2da15dc71ad95563ebcf2d9c1987a7b.jpg

    A pic with just the CCFL on.

    DSC_0027A_30a9da8df9bacec9791c6ae0488b11ea6c0645a3.jpg
     
  3. Mar 27, 2012 at 6:54 PM
    #3
    memario1214

    memario1214 Vivid Illumination Vendor

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    Attention to detail is amazing Tom! I will be frequenting this thread when I ditch my Mini D2S I have now and upgrade to an FX-R
     
  4. Mar 27, 2012 at 6:59 PM
    #4
    95SLE

    95SLE [OP] Starting to get cold outside

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    Believe me I asked a lot of questions via PM's. A big TY to ANT.
     
  5. Mar 27, 2012 at 7:00 PM
    #5
    Rich91710

    Rich91710 Well-Known Member

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    What is the (functional) difference between this kit and the kits that retrofit sells that don't require drilling and sealing to mount the projector?
    Are they not Bi-Xenon?
     
  6. Mar 27, 2012 at 7:07 PM
    #6
    Night

    Night Well-Known Member

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    You have gave me the confidence to do my own! You include specifics and turn this into a how-to! Nice truck!
     
  7. Mar 27, 2012 at 7:09 PM
    #7
    95SLE

    95SLE [OP] Starting to get cold outside

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    They are Bi-Xenon.


    When I was doing research I kept reading posts from guys, here on TW and on HID Planet, that they were not satisfied with the illumination and lightpattern of the H1 retrofit kit. The also said they eventfully replaced the H-1with the FX-R. The projector is the biggest difference, the FX-R is a better all around projector with better glass.



    I decided to bite the bullet and do the more complicated install.
     
  8. Mar 27, 2012 at 7:36 PM
    #8
    Night

    Night Well-Known Member

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    I thought the FX-R would be even more complicated but they are relatively still a simple install, did you follow a particular guide?
     
  9. Mar 27, 2012 at 7:39 PM
    #9
    Rich91710

    Rich91710 Well-Known Member

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    Gotcha'
    That does make sense. Ordering a spare set of lights would certainly take some stress out of the project.

    I assume we want the H4 relay.
     
  10. Mar 27, 2012 at 8:34 PM
    #10
    AsianAnts

    AsianAnts just an AnT

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    great TOM! good job looks really great!
     
  11. Mar 27, 2012 at 8:46 PM
    #11
    S7ICKlVlAN

    S7ICKlVlAN Cpt. Bubbleguts

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    Really nice work! Thanks for posting the pics.
     
  12. Mar 27, 2012 at 9:47 PM
    #12
    OverRated

    OverRated Well-Known Member

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    Nice! I'm going to use your thread as reference when I do mine! Waiting for spring break (next week) so I can start and take my sweet time!
     
  13. Mar 28, 2012 at 2:41 AM
    #13
    95SLE

    95SLE [OP] Starting to get cold outside

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    Correct on the relay.

    The spare set of headlamps is a blessing. There is no time factor to do the mod quickly. I just took my time and tries to measure twice and cut once.

    I had thought about a 3in hole saw but I believe there would not be enough clearance between the battery and the headlamp to support a deeper depth to the projector.
     
  14. Mar 28, 2012 at 5:36 AM
    #14
    Oury

    Oury Texas Taco

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    stuff and more stuff
    What is that red sealant called?
     
  15. Mar 28, 2012 at 5:42 AM
    #15
    95SLE

    95SLE [OP] Starting to get cold outside

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  16. Mar 28, 2012 at 6:00 AM
    #16
    oldtacomaguy

    oldtacomaguy four forty four

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    Nice job and great writeup Tom. Those lights were put to good use!
     
  17. Mar 28, 2012 at 6:06 AM
    #17
    Oury

    Oury Texas Taco

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  18. Mar 28, 2012 at 6:14 AM
    #18
    95SLE

    95SLE [OP] Starting to get cold outside

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    Take your time. It actually was a nice project that helped me learn additional quirks on how are Tacoma's are put together.

    The first under headlight trim panel I removed snapped so loud I thought I had broken the retainer clip. When I reinstalled it I made sure it was cleaned on both sides and I sprayed some quick detailer on the clip to make it easier to insert.


    Dave thank you so much for the donor headlamps. I feel it was a win win situation for both of us. I reused your packaging to store my old headlamps. I have a feeling I may be helping some local guys out with retrofits and my old headlamps may be used again.
     
  19. Mar 28, 2012 at 6:13 PM
    #19
    Rich91710

    Rich91710 Well-Known Member

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    I'll be blacking out the bowl as well, so I'm not concerned about the reflection of the projector as long as the shroud covers most of it.

    What do you think about the E46R-Extended?
     
  20. Mar 29, 2012 at 5:59 AM
    #20
    95SLE

    95SLE [OP] Starting to get cold outside

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    Custom XM Install, Window Tint, Intermittant Wiper Install, AVS Bug Deflector, Bed Mat, TRS FX-R retrofits, CIBIE fog and spot lamps, PIAA 510 lamps, Acess LE cover, Weathertech Digital floorr mats, LED interior lighting, Pioneer AVH-2300BT HU, Boston Acoustics speakers, JL Audio Amp, shorty antenna, leather wrap steering wheel cover, Viper security system.
    Thos is my first retrofit so i do not have any knowledge of the E46R-Extended. You might want to send a PM to AsianAnts. He was most helpfull to me with my retrofit.
     
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