Retrofitting Projectors into Stock 04 Housings

Blackram · Dec 23, 2013

I picked up a set of stock headlights the other day for my 04 for 20 bucks and am thinking of putting in some projectors. I currently have hid 9007 bulbs in there but need any of the other parts needed for the retrofit. Anyone know what parts are needed for this project? And where to get them?

Stangshcky12 · Dec 23, 2013

Retroshop has the parts
You'll need a mini h1 projector if you want a easy install
You'll need an h1 hid kit with a mopar specific 9007 harness which JJ sells

I'm in the process of doing this project now
I found that you have to grind out the bulb cover holder for the projector to sit right

Blackram · Dec 23, 2013

Stangshcky12 said:
Retroshop has the parts
You'll need a mini h1 projector if you want a easy install
You'll need an h1 hid kit with a mopar specific 9007 harness which JJ sells

I'm in the process of doing this project now
I found that you have to grind out the bulb cover holder for the projector to sit right

So I can get all this stuff from one place? Do you have a link?

atticusfaul · Dec 23, 2013

retroshop.us - jj is a vendor here too.

Sent from my iPad using Tapatalk HD

MegaMouseGW · Dec 23, 2013

Yup get with Jeremy. He sold me almost all the parts I needed for my project, less a couple halo's that he did not have in stock. DO a bit of research before you start on how to tear apart the old headlights and be careful to not break the housings while doing it. I am in the process of rebuilding mine on my 07 ram after some scumbag decided he was gonna try and steal them from me (glad I spent the money to have my kids go through self defense classes).
I am creating an adaptor to hopefully keep me from having to grind down the housing. Waiting on a few things to arrive before I can do anything about it though. Specifically the taps and drill bits I need to do what I want. Just be sure to reseal the headlights real well when you put them back together. Had to remove mine once due to water getting inside. That was before that scumbag tried to steal them.

Blackram · Dec 23, 2013

I did post over in the retro shop forum. I researched cracking the headlights open and I might just use this cheap set I picked up as a practice set before doing it to my real headlights. Then I can learn from any mistakes before doing it to my good set of lights.

Stangshcky12 · Dec 23, 2013

03-05 are really easy to open, I can open then in a few minutes at this point just don't force it
This is the part I'm ground down and drilled a hole through for wiring

You cant see it once the projector is installed

Blackram · Dec 23, 2013

How'd you get the chrome off the bucket?

MegaMouseGW · Dec 23, 2013

Blackram said:
How'd you get the chrome off the bucket?

Getting the chrome off can be done a couple ways. First use bleach. Takes a while to do but it will get it off. Second is aircraft paint remover. Be careful with it though seeing as it can eat the plastic.
Now after removal paint the bucket with a good etching primer. 2 or 3 coats will be fine. Then paint it the color that you want it to be. Make sure that before painting you clean the bucket with dawn dishwashing soap real good. Getting all the bleach or aircraft remover off.

I do not recommend the aircraft remover though seeing as it can destroy the bucket.
Another way is to take some sand paper and scuff up the chrome real well. Then use some etching primer. Again 3 coats is best, then paint.

:fish_h4h:

Blackram · Dec 23, 2013

Good tips, thanks. So as best I can guess since I already have the hid ballasts in place I would need the projectors and some h1 bulbs for the projectors?

Stangshcky12 · Dec 23, 2013

I used easy off oven cleaner, set it and forget it
Cleaned it after with a red scotch pad and dawn dish soap

Same thing for the shrouds, I soaked them in bleach too for a piece of mind

I also used adhesion promoter then an etching primer
Adhesion promoter is for plastic as etching primer is for metal basically

Blackram · Dec 23, 2013

Stangshcky12 said:
I used easy off oven cleaner, set it and forget it
Cleaned it after with a red scotch pad and dawn dish soap

Same thing for the shrouds, I soaked them in bleach too for a piece of mind

I also used adhesion promoter then an etching primer
Adhesion promoter is for plastic as etching primer is for metal basically

Now that you mentioned it I read somewhere about using easy off to remove the chrome.

Stangshcky12 · Dec 24, 2013

I hadn't lol
I used it to clean aluminum wheels before and new it was some mean stuff
I also knew the chrome on the bowls wasn't very tough to get off since cleaner wax took it off haha

Blackram · Dec 24, 2013

Stangshcky12 said:
I hadn't lol
I used it to clean aluminum wheels before and new it was some mean stuff
I also knew the chrome on the bowls wasn't very tough to get off since cleaner wax took it off haha

After reading up on it a little I found a couple posts about using easy off.

Just need a list of parts so I can get this stuff ordered. I would hate to just order the projectors and the h1 bulbs and then find out i need some additional parts.

Stangshcky12 · Dec 24, 2013

Mini H1 projectors
H1 bulbs (color of your choose)
HID ballasts
Mopar specific wiring harness
Halos if you choose too

You can go to retroshops site and order an HID kit for 02-05 ram then all you would new are the projectors

Blackram · Dec 24, 2013

Stangshcky12 said:
Mini H1 projectors
H1 bulbs (color of your choose)
HID ballasts
Mopar specific wiring harness
Halos if you choose too

You can go to retroshops site and order an HID kit for 02-05 ram then all you would new are the projectors

Well I already have ballasts and all the wiring from my current hid kit.

What do you think the chances are of getting these housings open with a heat gun? I don't really want to bake them in the oven unless absolutely necessary.

atticusfaul · Dec 24, 2013

Heat guns are probably too hot and the heat is too isolated. I popped mine open in the oven and it was super easy the first time. There is a step by step thread on here somewhere.

WhiteExpress · Dec 24, 2013

I would recommend you use the oven. The even deep heat makes this far far easier than trying with a heat gun.
Go with a lower temperature for longer, get all the adhesive 'soft' and it'll come right off!

A heat gun will deform the lens/housing quite easy (ask me how I know!)

Blackram · Dec 24, 2013

The wife isn't going to be happy about this in her oven.

WhiteExpress · Dec 24, 2013

Get a silicon cook sheet to put over the regular metal one.

Make sure you housing is spotless all over.
When the plastic gets warm/soft anything (Dirt sand etc) will sink in and ruin it!

Retrofitting Projectors into Stock 04 Housings

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