My Headlight Build: OEM projector D2S 5.0 Swap

[Solid State]

Now that I got my headlights open, it's time to start the build. I am swapping the new Morimoto mini D2S 5.0 into my oem projector housings. Will also be doing switchback boards, and the C Bar/ Halo kit from Diode Dynamics. I've liked the look of those since the first time I saw them. To me they look more a daytime driving light, then some riced out carnival lights. And, will more than likely be doing rgbw demon eyes, because I think it will look neat with the etched lenses. *These are all subject to change during the build.
I purchased the retro-quick kit from TRS around xmas time. They have since removed this kit, (they only show the 4.0 available) and I believe its due to the fact that they don't have updated brackets designed yet. (Edit: spoke with Austin at TRS and he said they are currently out of stock on the 5.0. Also, they recently became aware of the bracket issue, and are in process of building new ones!) I got the 4.0 brackets with the kit, and had to do some modifying to make them work. Will be taking my time on my build and updating as I go. Since this is all new to me as a first time retro fit, I will also include things I believe relevant to help out the next guy. Have learned so much from the members here, and want to give back where I can.

 

[Purplert]

Yay join the club, I assume you already have all parts on hand?


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[Solid State]

Opened up my OEM projector housings. Here is link outlining that processhttps://www.ramforum.com/threads/how-to-baking-open-and-re-sealing-headlig. Once opened, I finished taking everything apart. Signal led housing are just held in by 3 torx screws. Removing the inner reflector bowl was a little more challenging. Its held on by 3 ball and sockets. One of those being the adjuster. I heated the housing with a hairdryer, and used a snap ring tool to pry them apart. Couldn't get the plastic adjuster ball socket out. So, I removed the adjuster by turning it all the way out, then turned the whole adj part a quarter turn counter clockwise with a pair of channel locks. This freed things up so I could pull it out easier. Once everything was apart, I started mounting the new projector. I included a comparison of the oem vs the mini D2S 5.0. Oem on the left, D2S 5.0 on the right.

 

[Solid State]

As I stated earlier the quick kit came with the brackets for the 4.0 version. Had to modify the projector housing in two spots to make the bracket work. I discovered this while looking around in a headlight forum. Can't take credit, but passing along. On the D2S 4.0, the bottom screw to the housing is removed and replaced with a bracket screw. On the 5.0, this has been replaced by a stand off post. So, in order to make things work you need to grind down the post (used a dremel tool). I removed the 6 screws holding the lense on before doing any grinding. Once ground down, I re installed the lense and used the hole in the housing as a guide to drill out the hole. The second spot you need to take care of is on the back side of the projector. I had to grind down some of the projector housing so the bracket spacer would fit. Pics explaining the spots and what was done:

 

[Solid State]

Yay join the club, I assume you already have all parts on hand?


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Need to order the stuff from DD, and figure out how to wire it all up. But I think I've got everything else... Nice output shot!

 

[Solid State]

More pics of mounting bracket, and projector mounted to inner reflector bowl:

 

[Purplert]

If your interested I’m pretty sure I have a brand new set of DDs halo switchback that I was going to use two retros ago but never used them that’ll I’ll let go cheaper that what they cost through DD.


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[2019Classic]

More pics of mounting bracket, and projector mounted to inner reflector bowl:

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Can you tell me the length of those standoffs?

I’m doing the same mod but not from a kit. I just need to know the spacing. Also how thick is the bracket 1/8”?

Thanks

Jack


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[Solid State]

Can you tell me the length of those standoffs?

I’m doing the same mod but not from a kit. I just need to know the spacing. Also how thick is the bracket 1/8”?

Thanks

Jack


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Are you asking about the length of the spacers between the bracket and projector? 12mm,

 

[2019Classic]

Yes, those. Thanks!


That helped tremendously. I had to make a bracket since everyone was out of stock.

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