OEmassive Quad Projector Retrofit

I usually don't do a lot of headlights, but I promised a friend I'd go full custom on his set of OEmassive's. The reason these are a perfect candidate for quad projector swap is each projector has it's own mounting pivot points and individual level adjustments. Not to mention there is ample clearance behind them to stuff larger aftermarket projectors. They desperately need an upgrade as everything inside is CHEAP. So here's the to-do list:

-4ea Morimoto D2S 4.0 square projctors
-Custom designed and 3d printed projector mounting adapter plates
-Custom illuminated side marker
-Upgraded DRL/Turn signal LED's
-Matte black painted bezels
-Quad halos
-maybe more, you'll have to wait and see


Here we go
Fresh off the boat



My wife is gone for the weekend...so the oven is fair game


NOTE: These are stupid easy to get apart. OEmassive does not use devil snot glue like OEM Toyota. It is butyl rubber so in the over @ 270° for 10min and I just pulled them apart with my hands. No tools.

Violla



While the housings were hot, I took advantage and cleaned all the channels. Tip:
Keep the old sealant in a ball and it works like a sticky eraser to remove more from the headlights.



20min later


Here is the backside of the DRL boards. So many wires!!




Stock LED and boards for the Turn/DRL. Into the garbage they go.
For those with a keen eye; they use white LED's exclusively.. with an amber cover over every other LED to create the orange color for turn signal.


How the light shines through into the otter frosted lens



Next is to rip out those cheap optics.



What I would have given to have dual post adjustments when I did my quads...


Close up of the projector. No clue who makes it.


That's it for now, stay tuned for more build pics

 

The goods:

4 X EVERYTHING.


morimoto D2S 4.0 projectors+components

first I wanted to address the big ugly "glow bar" OEmassive has as the DRL. 2 things bothered me;
1) it stuck out unnecessarily far
2)it wasn't blacked out enough

Here is how it sits stock:



I trimmed the back tabs which let it sit further back in the channel and now flush. YEAAA


Tabs that were trimmed


Next was to tone down the big white ugly thing.
I contemplated the best route on this one without diminishing light output. I settled on masking off the front;


Traced and cut. FREEHAND YO


And after some matte black. This will cut down on all the ugly white and still give me a nice "window" for the LEDS to shine through



test fit. Now were getting somewhere




Next is the side reflector.
Go all out or go home right?

To continue my BLACKEDOUT theme, 1/8" smoked acrylic is what I'll be using


Into the CNC


All done.


The slots in the middle are groved from the backside. This will allow the LED strip to fit in. as seen here


Test fit on the side. NICEEEEE



Then onto my high/low beam brackets.
I modeled the OEM ones to get a perfect drop in fit


out of the printer. Projectors line up perfect!


The backside was honeycombed for reinforcement




Next to the OEM

 

*SNAPS FINGER*
DONE(wish it was that easy)


3D printed for test fitment


I designed a lip on the back to prevent it form falling out forward(will also give me a spot to plastic weld it in)


LED layout



CNC'd out a quick jig. Then heated/bent up plexiglass and formed it.


Plexi installed(it was also sanded with 400grit to give the light a nice glow)




But wait, there's more
There is a big flat spot on the inside, so I decided to draw up a matching "3 bar" reflector(like the side ones)



Cut out.

LED channels


It's a combination of 3d printed housings, with CNC'd acrylic inside.


Backside. All wiring done. I will go over all the board with adhesive just to make sure it's in there for good.


Then, all the housings were sanded and painted with Matte krylon. It's my favorite paint as it's not too dull(like flat) and not too shiny(like gloss)


ALL DONE!


Close up of the internals








Off:


Angry halos AKA Dragon eyes.


DRL amber on with dragon eyes



DRL's only


Dual color



Side markers

 

X3

 

In for updates!

 

Dang I was happy to see this, but I was really hoping to see that you were gonna use G5-R's.

 

I need a rectangle lens in order to fit the original shrouds. To my knowledge the G5's are only available in round 3.2" lens.

 

Yeah I haven't seen em in anything but round. Gonna be cool either way!

 

one day when you decide to do this for other people for money sign me up.

 

I like watching stuff like this

 

I'm walking the fine line between hobby and profession.

I like making stuff like this.
So it works out

 

Can’t wait to see the finished product

 

How hard would it be to upgrade the drl's on these housings? Of course I would like to upgrade the projectors, but for me the only complaint is that the drl's are not very bright.

 

I'm working on that now. The original led boards will be junked, and I will replace the entire "U" shape with new LED strips

 

Will that be easy to duplicate and sell that part for myself or others do to to our housings?

 

More than likely be a custom 1-off. But we'll see how it plays out. Still in design phase

 

I wanna watch..

 

me you

 

Back at it again..... I needed something to suck me back into TW, and this is going to help.