My Head Light Build thread. So Far...

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OC455

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As was suggested I should post my own build thread. I've posted pics of what I've done so far in other threads of my quad head lights.

So far here is what I've got.

Opened the head lights and test fit the Morimoto Mini D2S 4.0 projector in the low beam reflector.

Had to open up the hole at the back to 35mm or 1 and 3/8 inch. Used a small sanding drum on a Dremel to open it up. A little at a time for a good fit. Also removed the diffuser/glare guard.

I did not take a picture of the back of the reflector for the H11 bulb pattern. I used the inside of the raised portion of the reflector to guide how much to remove. First picture.

I removed the black ring off the back of the high beam for the 9006 bulb. I am going to use the Profile Hi-Lens LED projector there. They are on order. The Hi-Lens has a 19mm/3/4inch shaft and it looks to be a 3/4 inch hole in the reflector, so the only modification that may be needed is to grind off the small tabs that stick out off the back of the housing. Second picture.

The third picture I fitted the Mini D2S into the reflector. I had to clearance the bottom of the reflector for rotational alignment. 4th picture.

I used the horizontal reflector line to line up the projector.

I used the Gattling Gun 1.0 shroud and trimmed it to fit into the reflector housing. This was my first attempt. Probably going to get another set and use the first ones as a template. Pictures 5 and 6. Picture 8 with shroud on.

Picture 7 shows that there is 3 and 1/4 inches of height there. The Profile Hi-Lens is a hair over 3 inches in diameter. It is about 2 and 5/8s from the back to the front and shouldn't stick too far out past the high beam part of the reflector.

Pretty sure I am going to have to trim the OEM bezel to get everything to clear.

Don't know whether to go satin black or color match to the factory paint color (brilliant black). I also ordered Profile 3157 amber LED bulbs.821fdf5b887c8e99db969ed85e1c11e9.jpgaee0edd129818c1683faced7d6fade32.jpge4bedadda49ee1c96a41d21d75550f44.jpgdb9cd344ed0674be3ed55dea46c4149e.jpgc783e0159ac24f0cb1dc428d258bdd8b.jpg1ef98c90ccb0c1552a5c00a49603b3b2.jpgf6871c4b898d9cf325d664265a2f3f88.jpge2d063120b1ab8929cca756e5c611cf2.jpg

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OC455

OC455

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Received the Profile Hi-Lens today. They fit right in the high beam part of the reflector. Tight on the top, but it doesn't look like it touches. No modifications to the back of the reflector. Little bit disappointed that one of the Hi-Lens projectors sounds like it has something broken inside and rattling inside of it....will have to make a call to TRS.d429c9ddb6d9bc4334c15ccfc5317381.jpg0abd21cbfba0d0c50cdf5cd039d9f606.jpgc2c3b0e5acd4c949a83e14877d872086.jpg2f805131ecf97a52b492c7e0962b56bc.jpg468abcd6b12ba3e9fb9e9f1f2a6017c2.jpg

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firebuff17

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Looking good so far Chuck. Those projectors look good in there. Output will be amazing!
Are these my old quads by chance?
 
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OC455

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Looking good so far Chuck. Those projectors look good in there. Output will be amazing!
Are these my old quads by chance?

Yes Sir they are. Just taking my time with them and making sure I get them fitted right and set, so I don't have to mess with them after they all get hooked up.

I also purchased a set of Profile amber LED 3157 for the turn signals.
 

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If you get a chance can u get a picture of the high beam light output. Haven't really wanted to put a high quality light in the high beam since the projectors high beams are incredible. They have visually caught my eye a lot and think they look great in the housing. Also what kind of paint theme are u thinking of?

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OC455

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I only hooked up one light to see what kind of output it had. It's not bad.

I'll try to get a picture of it. I'm thinking satin black for the bezel or color matched to the brilliant black that my Ram is. Leaning more towards the satin black.

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What paint should I use for the best results for satin black?
 

Purplert

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Duplicolor has a low gloss engine enamel that comes out satin looking.


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RusslRam

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I used thisd2b92980e31ee4d50f6b0063ea9dd615.jpg

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OC455

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Sweet, won't have to look far then.
 
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The first picture is the head light sitting on a bar stool about 15 ft away from my garage door. Hi-Lens LED projector.

Second picture is the light shining down my driveway and across the road. Driveway is about 150 to 160ft long.

It is a pretty warm colored light. Kind of like the new LED spot lights on new police vehicles.

Very focused.aa98507e4d691776dd4807d894689af2.jpg5dc0cb432e8821918e4378dcae25e94d.jpg

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OC455

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If you get a chance can u get a picture of the high beam light output. Haven't really wanted to put a high quality light in the high beam since the projectors high beams are incredible. They have visually caught my eye a lot and think they look great in the housing. Also what kind of paint theme are u thinking of?

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RusslRam, let me know what you think. These set up as a high beam in-conjunction with a HID Bi-Xenon projector will be ridiculous. The throw down the road with the Hi-Lens should be very good. I pointed the housing down to show the light, even pointed low it shows a lot at distance.
 

RusslRam

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RusslRam, let me know what you think. These set up as a high beam in-conjunction with a HID Bi-Xenon projector will be ridiculous. The throw down the road with the Hi-Lens should be very good. I pointed the housing down to show the light, even pointed low it shows a lot at distance.
That has great light output. It might add distance to the projector high beams. Always good to have a back up in just in case the cutoff stops working.

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Might be a while before I can get these put all together. Too freakin cold right now to get them all set up. At least I can get them mostly done. :)

OnSale did an awesome job with his set. I wish he had a couple of night time shots of the light output with the Hi-Lens though. Would like to see how they look with everything running.
 
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Looking at my pictures again, I dropped the center point of the light down about 2ft from where I had it centered on the garage door. I would say these set and adjusted will be pretty good for sure.

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Following. Very excited to see how this turns out. I’m basically doing the same setup with different low beam projectors.

Going to color match mine in brilliant black.
 
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Started cleaning the Permaseal out of the channel of the headlight bucket. What a PITA. I used a heat gun and a small needle nose plier to pull out the Permaseal. I was doing it in small sections around the headlight bucket. Have to do small sections of it, once the Permaseal cools off it is next to impossible to get it to move. Just have to take care in heating the black plastic as it softens it a lot and can make it too malleable. It took about 30 to 45 minutes to do one headlight bucket.

Will work on the other one today.
 

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Started cleaning the Permaseal out of the channel of the headlight bucket. What a PITA. I used a heat gun and a small needle nose plier to pull out the Permaseal. I was doing it in small sections around the headlight bucket. Have to do small sections of it, once the Permaseal cools off it is next to impossible to get it to move. Just have to take care in heating the black plastic as it softens it a lot and can make it too malleable. It took about 30 to 45 minutes to do one headlight bucket.

Will work on the other one today.
Ill be starting my retrofit shortly. Same idea, but I opted for the H11 7.0 for the wider beam pattern. I'll be picking up the LED hi-beams too, should be a good combo. Did you have to do anything extra to wire the LED hi-beam in? I do not have them in hand yet, so I figured I would mention it since you just hooked em up.
 
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OC455

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No, I haven't wired anything as of yet. I'm still working on getting everything fitted right now. I am going to be contacting TRS for the info and products I may need to get it all running right.
 
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