HID Projector retrofit into 05-07 headlights

[AlaskanTrucker379]

This is my start of a projector retrofit. For now, This will just be an update thread with pictures and questions and such. When I am finished, I will turn it into an official log and write up.

Got my goodies in the mail today. FXR projectors and bulbs. I will be using my existing HID ballasts. Also got white LED hidden halos for inside my gattling gun shrouds.

Untitled by alaskantrucker379, on Flickr

Untitled by alaskantrucker379, on Flickr

Untitled by alaskantrucker379, on Flickr

This here is just a mock up. The trimming process is proving to be much more difficult and time consuming. The projectors need to be set much deeper it seems, I would like to try and get some bolts through the reflector too instead of just epoxy, but for that, I would need to get the projector alignment right. I guess I just need to get my truck inside and test the alignment on the garage door.

 

[slightlymodded]

Really interested in this. Been waiting for a good right up.

 

[jwlandry]

Me too

 

[AlaskanTrucker379]

I cannot get these FXR's to fit! The shrouds either touch the plastic lense, or the projectors bottom out on the header panel.

I think I will I try some different, more shallow Shrouds.

 

[verifine]

I cannot get these FXR's to fit! The shrouds either touch the plastic lense, or the projectors bottom out on the header panel.

I think I will I try some different, more shallow Shrouds.

Take the shrouds to a belt sander and take a small amount off at a time. Luckily the part of the shroud that has to be ground away will not be noticeable at the back of the headlight bucket. I had to do some trimming on my FXR retrofit to get the shrouds to stay on.Looks good so far almost like it came from the factory.

 

[AlaskanTrucker379]

The type of shrouds I bought, I guess are an older style and don't sit back as far as the newer ones do. The front of the shroud touches the plastic lens when I put the headlight back together. I ended up ordering a different set of shrouds and I will see if that helps anything.

The newer shrouds sit further back onto the projector and centric ring.

 

[mstng5point0]

Mine had morimoto d2s from the retrofit source

 

[AlaskanTrucker379]

^^ I'm not doing FXR's again in the 05-07 housings. I like the D2S/MiniH1 for size. They are just too tight with shrouds and too much work. I believe I got it to work, but it wasn't easy.... and I'm only half way done.

Untitled by alaskantrucker379, on Flickr

Untitled by alaskantrucker379, on Flickr

Untitled by alaskantrucker379, on Flickr


Pretty much done with the drivers side after my new shrouds. They still have some clearance issues with the lens. At least I got it in the general area and rotated correctly. I used 2 #8 screws and nuts to secure the top of the projector, then JB steel stick to attach the bottom of the projector to the inside of the reflector. I layered some aluminum foil to cover up my hole in the back of the reflector. I'm not too worried about it though as It will be sealed up on the back of the housing with a cap and silicone.

 

[NEVRNF]

Why does it look like you are getting a lot of light leakage from the back of the projector?

 

[cjfarm111]

I noticed that too

 

[AlaskanTrucker379]

Its not leaking light. I have white LED Halos behind the shrouds that are tied into the parking lights.

I have been working alot lately on other things and at my job, So i still havn't gotten to sealing the drivers side up or the passenger side yet.

 

[jwlandry]

they look good but I do agree with the mini shrouds. Ive been looking at more and more of them to do my own and they seem to be the go to shrouds to fit easily in the 05-07 housings.

 

[AlaskanTrucker379]

Butyl that I used to reseal the lights. This stuff is amazing.

Just stretch it out until it fits in the channel.

Heated back up in the oven, pressed back together, And a water test. Passed with flying colors. I even squirted water from behind the light.

Now all I have to do is seal up the back of the housing. Any ideas?

 

[Super Diesel]

Looks tight, man! I like it!

 

[AlaskanTrucker379]

Thanks. Its definitely not an easy thing to do. Its best to slowly work through it and trial and error as you go. I only just started on the second headlight.

 

[Clean-15]

Does that butyl harden a little after you bake it or does it stay gooey?


Sent from my iPhone using Tapatalk

 

[AlaskanTrucker379]

The oven softens it up, into a very playable, soft almost liquid like rubber, it allows you to press things back together tightly. Then as it cools, it hardens and creates a seal