My quad projector retrofit

hunterdan

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So, figured I'd start a somewhat diy for a simple projector retrofit into the quad housings. End goal is using basic chrome housings, paint the surround black, keep the reflectors chrome and keep the oem reflector high beam, which will be augmented by the projector high beam.
So, ordered all the parts Wednesday morning.
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Parts list is accurate, except I switched from the profile peak turns to diode dynamics switchback 3157s. I also had a set of ballasts to use, so I didn't order those.
Also ordered some jb kwik weld to hold the shrouds on.
Once I got home from work, I stripped the housings down, removed bulbs and wiring harness and threw the first one in the oven for 10 minutes at 225 degrees.
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Pulled it out and slowly worked the edges with a flat screwdriver trying to separate all the glue. Top and bottom are easy, it's the sides that get tricky. Had everything pretty loose, then popped back in the oven for another 7-10 minutes to reheat. Worked the inner side (closest to the grille) and once the clips were loose, was able to start peeling it apart, and it came apart fairly easily after that. You can see the glue separate from the lens, so just take it slow.
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Once I got the lens off, I popped the other light in and worked on removing the remaining glue from the housing. This is the hard part. Using a flat screwdriver I was able to work it and pull up chunks, but once it got cold, forget it. Pulled the other housingnout and repeated the process. This one fought me a bit more, took 3 hearings, and bumped the temp to 250, but less time. The higher temp seemed to really help. Once they were apart, I focused on removing the glue. Heating them at 250 for 5 minutes at a time seemed to really help speed the process. Getting all the glue out is only going to help the reseal process. It's a pain. But not impossible. I popped the reflectors out, will be reusing them, but need them out so I can paint the housings. Next step is cleaning up the frames and hitting them with some black.
This is the first time I've attempted something like this, so keeping the build simple. Plan is to have the housings painted by Friday, parts should all be here by Friday, and final fitment/install should be completed by Saturday.

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hunterdan

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Nice. Keep posting
Will do once I make more progress. Rain today and possibly Friday means painting might get pushed back til Saturday. Either way, looks like everything should be done this weekend.
 

hunterdan

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All my parts are scheduled to arrive today. Hoping the sun comes out here long enough to get a few coats of paint on the surrounds. I've got them cleaned and decreased, now drying. Nothing picture worthy really until I start to assemble everything. I forgot to bring one of my bigger unibits home from work, so I'll probably just run out and grab one this afternoon or tomorrow morning. Either that or use my dremel to enlarge the holes for the hid grommet.
 

hunterdan

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Ok, been busy this morning/afternoon. Painted my housings, twice. First time I tried a matte black that turned out more green than black. Went to grab a new can of paint from the store and the wind knocked a piece of plastic on top at which point stuck to the paint and peeled the paint off when I pulled it. So, had to strip the paint and start over. Anyway, got the housing painted black and while waiting for that to dry, I started fitting the projectors.
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Fitting the first projector took some time as I figured out what I needed and where things needed to go. I had to ream out the hole for the stock bulb to fit. I used a dremel with a sanding wheel and it took care of it in no time. At this time I was also fitting the projector shroud. I ordered the smallest shroud I could find to minimize any trimming. I still had to trim the bottom of the shroud because of the little hump in the reflector.
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At this point I tightened things down so they'd hold in position. I ran the wires for the high beam flap through the hole where the glare shield was. I wired up the flap to a 9006/9005 connector so that I can activate it with my standard high beams.
 

Treburkulosis

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Looking good! Subscribed!
 

hunterdan

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At this point, I needed to start figuring out the wiring. I had 2 9006 splitters and 2 h11 to 9006 adapters. I set the splitters up to activate the shutter in the projector and the 9005 led bulb I'm going to be using. Figuring out the wiring was time consuming. As I had to make sure all the negatives went to the negative leads on the ballasts and same for the positives. Since I am using h1 based projectors, my h1 bulbs had to be converted to an h11 connector. I had to pull the h1 spade terminals through the grommet, de-pin the 9006 connector on the adapter and feed the adapter leads through the now vacant holes on the grommet. This is what triggers the ballast to fire up the bulbs. I didn't take pictures here because your harness may differ. Once I figured out the first wiring harness, I went to the next housing and fit that projector into it. Making the same trim on the shroud. Once done, I finished up the second wiring harness. So, currently, I am waiting on paint to dry, I will need to test the wiring to make sure everything works, then I can pull the wiring back out, and seal up the housings.
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Once the paint is fully dry, I will pop the reflectors back in (yes I kept the stock amber).
 

hunterdan

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Plugged everything in to check for function. We've got lows, We've got highs, and we've got projector highs. Success!
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