Hella 90mm H9 projectors Installed in a 2001 Firebird (plenty of pics)

VIP1 · 2009-01-11 23:16:49

Sweet job, VIP. Thanks for the pic! :thumb:

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02-04-2009, 11:05 PM

#21

98 WS6

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Sweet job, VIP. Thanks for the pic!

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02-04-2009, 11:15 PM

#22

VIP1

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Thanks. Sorry for the delay.

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02-04-2009, 11:56 PM

#23

jorgez28

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looks good wish I was more mechanically inclined

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02-27-2009, 04:23 PM

#24

lo_jack

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Very nice. I have two questions, as I have been following this. No doubt you made refinements along the way.

HIDs are getting cheaper - you can ebay up a set that will allegedly fit an h9 housing for $100 now I guess. Have you looked at what's out there lately to see if there are more cost effective HID kits now that work with these projectors?

The shrouds - they are pretty nice. How did you do them, and if you had to do them again, would you go the same route? I was thinking fiberglassing on an old set as a mold and making some new ones...but that seems overcomplicated. Any thoughts on that?

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02-27-2009, 06:29 PM

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VIP1

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Quote:

Originally Posted by lo_jack

HIDs are getting cheaper - you can ebay up a set that will allegedly fit an h9 housing for $100 now I guess. Have you looked at what's out there lately to see if there are more cost effective HID kits now that work with these projectors?

Yes. HID kits have gotten much cheaper. Instead of ebay, check out DDM Tuning and Retrofit Source as alternatives (there are others). I'm looking into getting a 55watt Apexcone kit from DDM Tuning. I've heard mixed things about DDM Tuning recently though and the 55watt H9 kit is currently out of stock so I'll have to wait. Prices now vary $50 - $180 depending on the wattage and where you get the kit. Be careful with 55watt kits, they have been known to damage the chrome on the bowl of some smaller projectors (similar in size to the Camaro fog lights and a couple a little larger).

Quote:

Originally Posted by lo_jack

The shrouds - they are pretty nice. How did you do them, and if you had to do them again, would you go the same route? I was thinking fiberglassing on an old set as a mold and making some new ones...but that seems overcomplicated. Any thoughts on that?

Mine aren't fiberglass (I don't know how). Its the stock plastic shroud with bent thin aluminum flashing for the main area secured with rivets and molded in around the edges with plastic epoxy and a small amount of body filler over the epoxy to get the contour just right (filled in minor highs/lows/pits). That was followed by the normal painting process. On the back-side, the rivets are coated with silicone to prevent water getting past them. I should take some more pictures of the back and my process. Sanding/shaping the epoxy took a long time. Also, sometimes the backside retains water. I need to trim it. If I were to do it again, I'd explore other options. I'm not sure what (flat plexi, vacuform plexi, fiberglass, other?).

Last edited by VIP1; 02-27-2009 at 06:35 PM.

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03-02-2009, 10:16 AM

#26

lo_jack

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Very interesting. Thanks for the update. I'm riding dirty with my shrouds half off currently. I was thinking about making some new shrouds out of fiberglass, casting off a paper mache type mold, but I don't know if that is doable or not.

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03-07-2009, 05:26 AM

#27

taws6

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Quote:

You have to admire the determination to complete the project the right way.

Good job.

Yea, looks a great job, and the shrouds look flawless too.

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03-07-2009, 07:50 AM

#28

98 WS6

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Hey VIP, How did you do the shroud?
Edit: Whoops my bad, didn't see that post. Geeze you put a lot of time into those!

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03-07-2009, 11:51 AM

#29

VIP1

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Thanks for the compliments.

Making the shrouds took much longer than installing the projectors.

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03-10-2009, 10:37 AM

#30

lo_jack

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This is cool. You asked me about this a long time ago, now I asked you for an update. It comes full circle, and the whole thing has improved drastically. I'm going to be getting a set of 35w from Retrofit. I was concerned about the heat from a 55w on these 90mms myself. I replaced all my wiring with heavier gauge from the gray factory connector up, and the housings make me all the more nervous. Are you going to put the 55w into the Hellas when you do that upgrade?

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03-10-2009, 11:04 AM

#31

VIP1

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Quote:

Originally Posted by lo_jack

Are you going to put the 55w into the Hellas when you do that upgrade?

I'm considering it.

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03-10-2009, 12:40 PM

#32

cbr600rx7

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Very nice. At first i was not sure but after seeing them at night i am convinced. Good project man.

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04-04-2009, 10:05 PM

#33

VIP1

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Today I installed an upgraded wire harness for the low beams.

Here are the highlights:
* 14 AWG wire throughout
* All connections are soldered
* Indiviual Relay and Fuse (15AMP) for each bulb

The bulk of the wire is a 14/4 cable that I found at Home Depot. It has a thick rubber casing and (4) 14 AWG wires that also have thick insulation.

Since Male H9 connectors don't exist, I had to make my own by breaking a pair of new H9 bulbs to use their bases.

In the first few pictures the insulation at ends with the bulb connectors is cut/split. I waited until the harness was installed in the car to trim the extra insulation and wrap the ends with electrical tape. The result is that the outer insulation goes up to the connectors. The reason I did it this way is that I can easily go back to halogen. In which case, I'd remove the electrical tape and peel back the split insulation. Then the exposed wires would reach the bulbs.

I tapped into power at the AUX power terminal and used a nut I already had to secure the connector to the terminal on top the exiting bundle. I tapped into ground at an existing ground point. It both locations I used a file and wire brush to make sure I had a good clean connection.