Check out this thread for some background information. Disclaimer: Like any reasonable adult, in doing this mod you take full responsibility for your actions.
Materials needed:
Tools needed:
Procedure
Take off the bumper and remove the headlights
Open up the headlights (see e-ride’s thread for pics and more detail)
Remove the reflectors from the housing
Cut a hole in the back of the reflector that will accept the projector
Cut the back of the housing to gain access to bolts
Materials needed:
- OEM HID setup which consists of 2 HID projectors, 2 ballasts/igniters, 2 D2S bulbs
- H4 wiring harness
- JB-Weld
- 8 3” bolts w/ nuts and washers
- clear outdoor caulk/silicone
- high temp spray paint, primer
- bag of #8 washers (optional, to do a color mod)
- metal stove burner trays (optional)
- electrical tape
- a small amount of any kind of paint
- masking tape
Tools needed:
- wrench/socket set with various sizes
- screwdriver
- drill with various bits
- dremel tool with cutting wheel and various bits (cheap-o one here)
- level
- hacksaw
- tape measure
- mask, eye protection, gloves
- metal snips (optional)
Procedure
Take off the bumper and remove the headlights
- 3 bolts hold each headlight to the frame. Be sure to unplug the 2 bulb connectors as you remove the lights
- remove the 2 bulbs (low beam and turn signal)
- remove the black metal bar on top of the headlight (2 bolts on each)
Open up the headlights (see e-ride’s thread for pics and more detail)
- preheat your oven to 200-250 degrees and place each headlight inside, one at a time, on a tray lined with a moist towel
- put on some gloves and wait approximately 5 minutes for the adhesive to soften
- take it out and use a flat-head screwdriver or other flat tool to pry open a corner
- once you open enough to get some fingers in, use your fingers to pull the clear front lens apart from the rest of the housing
Remove the reflectors from the housing
- using a 10mm wrench, turn the adjustment screw counterclockwise until it releases the reflector. The screw stays in place – it’s the reflector that is moved.
- pull CAREFULLY on the two pivoting balls. It takes some force to release them, and I ended up breaking two of them. Remove the turn signal reflector the same way (it only has 2 pivoting balls)
Cut a hole in the back of the reflector that will accept the projector
- take a piece of cardboard and cut a hole in it so that it fits the rear of the projector bowl. Cut it a bit bigger vertically to allow for some wiggle room, but be sure not to cut it too big on the corners, where you’ll need to drill some holes to attach the projector with nuts/bolts. If you cut too big of a hole, you’ll have nothing to bolt the projector to.
- using this template, trace an outline on the reflector. Make sure it is somewhat centered (for aesthetic reasons more than anything)
- cut the hole using the cutting wheel on your dremel. As you cut, absurd amounts of an unknown white dust will be released, so be sure to use some sort of mask, eye protection, and gloves. As you can see in the picture, I drilled a hole in each of the corners of my template to kind of guide me, as I found it was easier to cut from the back than inside the reflector. In hindsight, I should have just traced the template on the back of the reflector. After you finish cutting the hole, give it a little test fitting to make sure you didn’t cut it too big or too small.
Cut the back of the housing to gain access to bolts
- there’s no real pretty way to do this, but basically just use a hacksaw or similar and cut an opening on the back of the black housing so you can gain access to adjust and glue the bolts later on. I didn’t do this until much later, but in hindsight it would have been helpful to have done it at this step. It should be about this big: