Anyone else interested in this type of stuff?

I'm getting ready to do my first real HID retro into my car. Using Ebay projectors as the base head lights. They will receive E55 bi-xenon projectors, Bosch Gen 2 ballasts, D2S bulbs and some other little interesting mods.

I'll also be doing LED turn signals too.

how much

How much for me to do it for someone else or how much is my set up costing?

Ben does it, you could send him a PM

I thought that u were marketing these ? so how much for u to do it for other ppl.

Nope, not marketing them. Just wanting to see if anyone else has a retro in there car.

I might consider doing a set up for someone, PM me though.

there was a link in one of discussions I was in, in bling bling.

Someone showed how he put audi s4 projectors in a 2g housing. I think I had it titled for 1gb projectors.

I'm in the process of doing a retro right now. I've been using an old set of ebay projectors as my test housings.

I'm using Infinity FX bi-xenon projectors with Philips D2S bulbs and Hella Gen 3 ballasts. I also swapped clear TSX lenses on the FX projectors. The projectors fit great in the housings. I've got the mounting done to the stock headlight adjusters.

I haven't done the retro into the headlights currently on the car. I'm still sourcing parts for the LED turn signals, but I do have all the electronics figured out.

What LEDs are you using for the turns Mark?

I'll take either amber Superflux or Cree P4's. I'm having trouble finding enough of them in amber; I'd like enough to play with... maybe about 120 of them. There's lots of eBay knockoffs, but I don't want those.

Are you buying local or online?

Not sure if you are on HID Planet but this guy is using Superflex narrow angle amber LEDs and it looks pretty good, really bright.

http://www.hidplanet.com/forums/viewtopic.php?t=50244

I've been looking online. I've learned a LOT from that site.

I'm still deciding on the beam angle. On the front end, I'm going to run the LEDs at 70mA through 3 voltage regulators (left turn, right turn, signal) with 3 PWMs for dimming control. I figure 18 LEDs per light. I still have to figure out the DSM flasher, as I'm sure it won't like LEDs instead of incandescent bulbs.

Are you going to boost the Bosch ballast you're using?

Talk to azdave on HIDPlanet. He makes a modified Eclipse flasher.

I will be boosting the ballasts. Plus running a pwm so I can flash and boost them. Maybe then people will move on the highway lol

Starting my retro officially now.

Parts so far:
E55 Bi-Xenon Projectors
Bosch AL Gen 2 Ballasts
Osram Bulbs
OEM Talon Headlights

Pictures:




Oh, because I will be boosting the ballasts I need to keep them cool so, check this out.


Heat sink and fan.

UPDATES!!

So I picked up some cheap Talon headlights today.


Now for a bit of tech.
Opening Headlights With an Oven
Mechanics Gloves (to handle the lights)
Paint Scraper
Exacto Knife
Oven
Baking Sheet
Damp Towel

1. Grab your baking sheet and cover it with a damp towel. Wet things won't burn and you don't want to melt your headlight.
2. Remove the bulbs and metal clips from your headlights.
3. Place the head light on the baking sheet and put it all in the oven. Don't let the head light touch the sides of the oven.
4. Turn the oven to 210* and set the timer for 8 minutes.
5. Put on your Mechanics Gloves and wait.
6. When the timer goes off pull the light out and use the paint scraper to start prying the light apart. I use the scraper because it's flexable so it shouldn't break anything. Use the Exacto knife to cut the sealant. (Careful the sealant is some sticky sh!t!)
7. Your headlights are now apart.


Both headlights separated with all there pieces removed. I likely will not be putting the amber corners back in, remember I want to use LEDs. The lenses need to be cleaned up/restored and have the flutes removed, I'll likely do that tonight and maybe even paint the chrome bezels. Need to see what paint I have sitting around.


Also took some measurements since I had them all apart.
Low beam section:



High beam section:



The E55s will fit no problem in the low beam side.
I've decided to run FX-R projectors from The Retrofit Source in the high beam section.




I'll be using Phillips bulbs and 55w digital ballasts. Should be awesome

My E55 projectors left Cali at 1:15am, I should hopefully have them in another few days.

Pictures!

I started to sand and polish the lenses. Here's some shots of the sanding progress, I sanded the flutes out of the inside.



I then started to polish them but I'm not pleased with the results yet. The flutes are still sort of visible and the my arms/hands are sore. I'm going to grab a Power Ball Mini and give that a shot. Should do a beater/quicker job then my hands. I might have to sand the inside more to get the flutes out.

Also painted the chrome shrouds flat black. This is after the first coat, too dark to get more pictures.
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/HID%20Retro/IMGP5126.jpg[/img]

After 3 coats each.
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/HID%20Retro/IMGP5130.jpg[/img]

looks like a nice setup. You will be really happy with the fx-r's keep up the good work!

Thanks Ben!

Looks awesome except trying to over run / boost the ballasts is just asking for a fire hazard.

Good luck man

That's why I'm potting and running the heat sink and fan.
I might be adding a self resetting thermal fuse

I'm not gonna burn down the car nor share all my secrets just yet.

It's been a good morning so far


Let see your PnP kit have a cut off like this!


Bright

Pulled the reflector bowls from the stock housing tonight.


I have most the mounting hardware, just need some brackets and it's time for the real fun to begin.

I've also played around with color modding the E55s. I've got more work to do with that but I'm pleased with the results so far.

I ARE FINISHED!!
















Nah, I'm just kidding.
Projectors are ready for mounting in the passenger reflector bowl. Hopefully will have both mounted by the end of the weekend.


I had to cut LOTS out of the reflector bowl and notch the bottom for the Bi Xenon solenoid.



Then I decided to play around with the power supply. Should look sweet




I still need to order some bezels for the projectors.
As for the projectors I want to mount in the high beam reflector bowl, I'm not sure about that. Found a local suppler which carries the FX-R projector so we're gonna meet up next week when I've got some free time and have a look to see if it will fit.

Thanks guys!!

Got some work done over the weekend.
Both reflector bowls are cut. I'll get the projectors mounted tomorrow morning. I need some more high heat black before the bowls get painted.


Cleaned up the headlight housings to I could paint them. High heat black inside, Hammered Grey outside.





Worked on color modding the E55s too. Very pleased with results.
Stock


Color modded



That's it for now!

Got 1 projector mounted today.


The lower screws are WAY too long. I need 1" screws and not 1.5". I'll try to get to the store to exchange the ones I have and then get the other projector mounted.
Almost in the home stretch.

Bought some FX-R Bi Xenon off of Ken over at Xenmod.ca.
Must say I'm very impressed with both the projectors and Ken's service.

Pictures:



Cut off, I didn't get a shot of the High Beam.


Trying to get it in the reflector bowl.



Then I broke it so, JB Weld to the rescue!


Gonna shave the sides of the projectors and get them fitted tonight!

FX-Rs mocked in place, looks pretty bad ass imo.



Slowly moving forward, looking into my LED turn signals. I'm trying to find a small set of round fogs that I can steal the lenses from so I will be able to do a projector set up. I've found 1 or 2 that I can use but with blue or ion lenses which will change the color of the LEDs I think.

As for the LEDs, I'll be using Phillips Lumiled Luxeon K2s in amber.
Specs:
- 35 lm @ 350mA
- 65 lm @ 700mA
- 1500mA - Max Drive Current
- 3.4Vf - Forward Voltage
- 590nm - Color Temperature



I think anywhere from 4-6 per side will be REALLY bright. I've got to run a heat sink under them too as heat can kill an LED quickly!

I'll also share a bit about the FX-R and what bulbs I'll be running.
The FX-Rs will be running Phillips DL-50 'Fat boys'. They are a 50W Xenon bulb.
I'll be running an aftermarket 55w ballast with adapters to plug into the OEM bulbs. I haven't decided on a brand yet, maybe something from Retrofit Solutions as people seem to like them.

Going to get both E55s mounted over the weekend and start on the wiring too.

Ordered a bunch of stuff from Matt at The Retrofit Source today. Can't wait to get this stuff.

Gattling Gun shrouds (2 pairs)


ZKW Replica Clear Lens for the E55s (sharper cut off and more color with these babies)


Some Phillips 85122+ D2S bulbs. These will go into the FX-Rs until I can track down some DL-50s


I'm on the fence about the LED projector signals right now. I'm not too up on spending close to $100 on fog lights just for the lenses. So I might just remove the amber from my current lights and then just run LEDs behind them. It won't look as pretty but will still be what I want.

Welcome.

Who's ready for some updates? Got some real progress down today imo.

Before starting any job, make sure you have beverages, Cold Certified beverages.


The projector mounting brackets after being trimmed and tapped for the 10-24 screws. .79 cents for 4 at Home Depot.


The brackets on the projector.


1"x10-24 machine screws with a lock washer and nut holding them to the projectors.


Mock up mounting of the projectors in the driver side bowl.


The rotational adjustment screw.


My fabulous JB Weld job to repair the driver side reflector bowl.



I don't always drink beer but when I do, I prefer Dos Equis!


The passenger side reflector bowl with the E55 mounted up.

[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/HID%20Retro/IMGP0064.jpg[/img]

I used sealing washers and nylock nuts. This thing won't move at all.
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/HID%20Retro/IMGP0065.jpg[/img]

Pitch adjustment screw. I need a longer one, it's currently 2" and I have no adjustment. Going to try 2.25 or even 2.5" to see if that will work for me.
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/HID%20Retro/IMGP0066.jpg[/img]

Some pictures of the projectors/reflector bowl mounted back in the headlight housing.
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/HID%20Retro/IMGP0068.jpg[/img]
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/HID%20Retro/IMGP0069.jpg[/img]

With the lens back on, this is gonna look bad ass imo.
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/HID%20Retro/IMGP0067.jpg[/img]

Here's a little beam shot to boot, nice and level, rotation isn't off, I'm very happy so far.
[img]http://img.photobucket.com/albums/v87/G2Rac/96%20Talon%20TSI%20AWD/HID%20Retro/IMGP0062.jpg[/img]

Now once I get the other projector mounted and some longer screws (again), I can mount them to the car and aim them. I can't wait

Got all my stuff from Matt at The Retrofit Source. Very pleased, fast shipping, great prices.
Here's all the parts:


Also the Phillips bulbs, these fit in my FX-Rs were the Osram bulbs did not.


Tonight, I installed the clear lenses into my E55s. What's the difference, well pictures speak a thousand words. The following picture is the stock E55 lens, you can see the circular grooves in the lens.


Here's the the clear lens, a perfectly clear lens.


E55 projector with no lens, you can see the shield nicely in this picture.


Some shots of the projectors with the new clear lenses.



Output shot, maybe 8ft away, you can see a bit more color. This will also give that nice color flicker when looking at the lights as the car is driving down the road. Color flicker is that changing from white to blue to purple.


I will have to do serious trimmings on those bezels to make them fit, plus paint some of the hardware so it blends into the housing.

Also, I got some LED strips with the lights, opinions?

I have to admit, I really like the LED strips. And there is a ton of serious work going into these headlights, but they are turning out amazing IMO.

I'm very interested in the LED strips though... do you have a link to them? Are they these guys?

Excellent work...I love seeing post like this. Gives me the courage to get my own projects underway.

Excellent can't wait to see the final product.

Thanks, glad you like the project. It's a retarded amount of work to get everything how I want it but in the end it will pay off.
I'm still not sure about the LED Strips, I might try some other things and see what I think. I'll have to figure out a way to paint the strip black so it blends into the headlight. I really wise they were long enough for the complete headlight.

That link is correct. I did get the strips from Matt @ TRS.



Thanks!
I can't wait to see them done either lol.

Thing i like best about this thread though, is that it's play by play photographs of what you've done, so really, when someone else goes to do a project similar to what you're doing, they can use it as reference.

Edit: hey, if you're not going to do anything with the strips... you could send them my way

Glad you like it. I'm hoping people can learn from what I'm doing. Even documenting some of my mistakes lol.

I'll let you know if I use the strips or not.

Looks awesome Anthony. Love this thread. You should try and get a LED bottom setup much like the Audi's, more spaced out, and set those up DRLs

The Audis actually use Phillips LEDs for their DRLs. They are larger and pricey. I think I'm just going to forget the LED strip (might use the strip some where else though need to see how bright it is first. I'm going to rewire my signal/marker lights to act as my DRLs.

Did some more work on the retro tonight.
Started getting the shrouds ready for the E55s. As you can see the inside needs to be trimmed to fit the projector.


After some cutting with the dremal.


After sanding to pretty up the cuts.


That's where the shrouds will wait for now. I want to get the projectors aimed before I do anymore work.

Mounted the reflector bowls into the headlights. Going to aim them in a week or so (having odd days off sucks).

I intended to have output pictures by now of the lights all aimed. However, things didn't go as planned.

I was getting set up to aim the lights when I looked at the back and noticed this.


After some choice words at my dumb ass self for not checking ahead of time, I drove home. Out came the dremel and plastic started disappearing.
This is what I was left with.


I can now connect and change my bulbs. I'm going to go to Home Depot and use some plumbing supplies to close it up again.

Also figured out a use for the LED strips. Turn signals!



I just coiled them up and glued them to the stock signal reflector.


A bit too blue for my taste so I've got an idea to change that. I'll be wiring them as signals only. Not what I wanted but I really don't want to spend too much more money on this project right now.

I'll be aim the lights tonight and after that start to trim the bezels.

Well, after wiring the lights wrong, being all pissed off, I finally figured out that the wiring diagram I found online was wrong.

Here's the wire call outs for a 96 Talon.
Black - Common Ground
Green - Low Beam 12V+
Pink - High Beam 12V+

So after that was corrected, I plugged the lights in for a little test action. I will aim them tomorrow. Right now the beam is not centered at all and the cut off is not horizontal. I'll correct it tomorrow.

Started aiming the lights tonight....
The driver's side is not aligned at all, I had to redrill one of the mounting holes, a bit better now but still needs to move. I'll fix it tomorrow.

Stock halogens


Mis-aligned and unlevel driver side E55.


Driver side FX-R, I want to bring this one up a bit but other then that it looks good to me.

Those are ridiculously bright! That's only one side too eh? With both sides working they will be intense!