For those of you with Sonar projector headlights and DDM (or similar) HID kits, I wanted to ask a question that I couldn't quite find an answer to with a search.

I was excited to put these things in when I realized that, for the life of me, I couldn't figure out how to get the bulb in. There's a bit of metal in the small groove blocking the wire...thing...from going in the only way I could imagine it fitting. Does that have to be ground out, or...? I haven't run across any posts here stating that the Camaro Sonars have to be modified; everything is, basically, "it's a tight fit, but it'll go." This is not even close.

I've attached a picture from my phone. Perhaps I'm just an idiot. It's like this in both the left and right headlights. Is this a casting malfunction? Or did they start doing this to PREVENT the HID lights from fitting? Thoughts?

 

order some real projectors designed for HID's and retrofit them. Thats the best solution.

 

quick search https://ls1tech.com/forums/appearanc...-mounting.html

 

They do that on purpose as they are technically not for HID. I noticed this as well.

BUT, at least with my HID bulbs, they fit in there if I lined them up just right. They would slide right in.

In that link posted, the bulb was being put in the way it is supposed to be normally, but it won't work that way. You have to put it in with the return wire in one of the corners. I forget which corner, but look at the base of the bulb, then look at the socket, line up the nubs and it'll go in OK.

I don't remember if I still have my old headlights or not. I think I don't but if I do I'll take pics of what I mean.

 

Yes, I've seen this. However, my problem is not with the base.

In these photos:



you can see the blue part (return wire?) of the bulb goes into the groove...Mine will not. There is metal in the way. (Please refer to blurry attachment in first post.)

That makes a little more sense...however, I feel like I would have to mangle the bulb to try and do that.

 

Just as an update -- the bulbs will definitely NOT fit in, no matter how much manipulation I try. The only way I can foresee doing this is to grind out the metal in that channel. (Then the base is probably going to be off.) Ugh.

And for those who are wondering, I'm pretty sure I got the right bulbs:

Bulb Color: 5000K
Bulb Type: H1
Wattage: 35 Watt

 

Not sure why it isn't fitting. Mine just slid right in

Where did you get the HIDs? I wonder if there is a difference in the bulbs that you have vs the ones I have. I wonder if my return wire sits slightly close to the glass, or maybe the glass is slightly smaller in diameter...

 

I think i had to do the same on mine, it's been a while since I have installed mine for the first time. I grabbed a filer and just filed it down.

 

I thought about ordering some FX35 projectors and fixing my K2Motors. I think they were mounted crooked. The cutoff on both lenses isn't level. I'd have to seriously tweak the mounting bracket to get the HL assy to rotate vertically to fix it.

 

I got them from DDM in the past month or so. I haven't had time to do much by way of installing them. I guess I was hoping for a bit more "plug-n-play." It may very well be that the bulbs are different...?

(On a side note, do you have any pics or info on how you wired them up? I think, among other things, I read that you had switched the prongs in the stock harness so you didn't have to plug 'em in backwards...?)

I definitely just drilled it out (now to get the little shavings out of the projector). So now the bulb fits, albeit just so. I will also have to notch the base to get it to seat all the way...

 

I'll bet the DDM bulbs are slightly thicker, just enough that they won't fit. It was tight with my Xentec bulbs.

What I did to switch the wiring around is fairly simple. On the 9006 plug, unclip the plastic retainer. Then use a thin needle or something to poke down the little square gap on the inside of the plug. This releases the locking tab. Then pull the wire out the back. If it don't pull out easily, don't force it, you just don't have the tab quite unlocked yet. Then switch the position of the wires (make sure to check that tab and bend it back outward a bit if it is folded flat) and snap the retainer back on.

 

Looks like there was some kind of problem with the casting and the metal was left in there.

 

So I finally got them in over the weekend. Overall, I ended up having to drill out the metal from the headlamp assembly, notch the base of the bulb, and grind down the two little nubs on the base of the bulb to get it to seat all the way. Not terrible work, by any means (thankfully, I have a Dremel tool).

However, when it came around to aiming the projectors, the Left/Right screw on the passenger side stripped out. So now they're all janky. !@#$. I think I'm going to have take the brackets off of the old headlights and swap them in so that I can get them adjusted correctly.

 

Wow. Sorry you've had such a hard time with them. Mine went pretty smoothly.

 

I didnt have to modify anything to get the bulbs to fit. Mine slid right in and I just popped the little clip over the top and I was done. I'm running Sonars with DDM 55W ballast and H1 bulbs.

 

Yeah, this is what I was expecting to do when I ordered everything.

Seriously, I think every time I try to make some improvement to my car, I always hit some sort of snag. Ugh. (Before the lights, the guy who installed my exhaust tips welded them on unevenly -- one was 1/2 inch away from the bumper, the other was a full inch.)

 

Are they supposed to be H1? Is that the same base as 9006/9005 (stock for 98-02 Camaro)??

 

The Sonar projectors use the same 9005 bulb for the high beam, but they use an H1 bulb in the projector. If you use the stock halogen H1 bulb that comes with it (and why would you do that ) It has an adapter that plugs the 9006 harness into the H1 bulb. H1 is totally different from 9006.

 

Ah just in case anyone cares... It turns out the screw wasn't stripped out -- the passenger light housing itself was hitting a spot where the fender is bolted up to the car. This prevented it from moving out as far as I needed it to. (Kind of hard to explain...can get pictures if need be.)

I did the best I could with alignment, but, as I mentioned, I can't get the passenger side to adjust far enough out horizontally. (See attached photos.) Also, both lights seem to be tilted anyway -- both up toward the center of the car -- making the cutoff a little wonky. I'm not so worried about the driver's side, but I'm afraid the passenger side's tilt is going to glare into oncoming traffic... Ugh.

If anyone has any suggestions as to how to level out the cutoff...I'm all ears.

 

When installing my sonar housings, I bent that fender/headlight mount tab thing to get the lights to adjust outward more. I dont have any pics but if you look at what is hitting it easy to tell and it doesnt seem to matter if you bend it. Also where the housing has the two slip mounts on the rear, I cut down about 3/8" to get the housing low enough to where the hood didnt push the light down and change the alignment. There is still a gap between the bumper cover and housing but I'll deal with that later. Hopefully that will help you get adjusted better.