Automotive lighting FAQ - Generic procedure for install of OEM projectors into reflector style headlamp

If they are not quad beam (separate high low reflectors), they might be available on the aftermarked. It will simplify install alot.
Ideally, they would have to be of the clear lens type. Making textured front lens clear is only possible if they are made in plastic. The sanding/polishing is very time consuming and can easily end up in a dead end project.
Most of the after marked headlamps have poor quality optics and sometimes even weatherproofing suffers, but that can be optimized. Weatherproofing is fixed by re-siliconing the front glass. Getting world class lighting performance consists of finding the biggest OEM projector unit that will fit in there. Ususally its the vertical hight and depth that will limit the choice. An easy route to get projector units mounted is to make a backplate out of lexan: (Lexan is described Tools and Materials page):
Do not mount projector too far back in the housing, the light that would normally hit ground around 5m in front of car will hit bottom of housing and be reflected up in sky. Optically, you can mount the projector unit as close to the front lens as you desire, but appearnce will suffer the closer you get. Projector units mounted too far out will stick oddly out in the front of the housing, decreasing overall cosmetic appearance (imagine how that would look in picture below!).


There is 3 dimensions of mounting that are important:

  • Vertical
  • Horisontal
  • Rotational - Use reflector lines as reference.

    Area on the side of the projector unit can be made prettier by filling up space around with a custom made cover. In the picture above Josh is showing his cover which are made out of a wheel cover. Finding materials for a cover is only linited to imagination. It can be custom made in high temp epoxy putty, sanded down and send to plastic chroming or simply painted with flat black. It can be cut out from big cofee cans or stainless steel lids that mom use for covering pots. Polished stainless steel is mistakenly close to the finish of high gloss aluminized surface. Other examples are metal roof flashing for vent pipe, metal lamp shade, assorted plumbing parts (a 4" to 3" ABS reducer fits great for large Bi-Xenon projector units). The important part is that shape is cylindric and/or conic. Take a tour with projector unit to your local kitchen store, Walmart, Home Depot etc.
    Note that (stainless) steel is the most time consuming material. Aluminum is softer, plastic is easier. Being able to use a powerful scissor is a great advantage.



    http://www.hidtech.com/ sells premade projector enclosures for projector unit. The types they have seem to be intended for Bi-Xenon projector versions originating OEM from 2002+ vehicles. They tend to have larger curved lens than earlier years projector units. So make sure hole diameter is not too big.

    Does shroud design affect temperature in headlight?

    Temprature inside headlamp is affected by two sources:

  • Radiation. Light shining on surface. If your shroud is black on inside it will absorb all light energy and get warmer.
  • Air getting warmed up. This is mostly dependant on air volume that is around bulb. If shroud is covering entire area between original reflector and new projector unit, the shroud will be warm. Herman recommends to make a few holes in original reflector, so that warm air can move out of this chamber into the rest of healight. The original refelctor is no longer in use and thee holes cannot be seen from the front.

    more: http://www.network54.com/Hide/Forum/thread?forumid=216460&messageid=1066284248&lp=1068501965

    How do I cover up the rear end of projector unit?

    Most common way is to leave rear end of hid bulb and bulb connector unsealed, making connection prone for intrusion of liquids. Herman would never recommned it. Something similar to the Hella 90mm can be made for a a OEM HID projector. Instead of a cylider, make a cone: http://hanker.tripod.com/headlight-level3-project-low-beam-mods.htm A CV joint from a small car (Fiat, Ford Aspire, etc) work, but they will require some extra space behinf headlight.

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