I figured It was time to release some pictures. Some know I have been working on a retrofit for the headlights of my T/A. After much research it was clear a full size OEM projector would be the only projector to use. I looked in the BLS kit but wanted to retrofit my own design. I am using RX330 AFS projectors, TRS Morimoto 50 watt Ballasts, for the time being I have the 4300K factory HID D2S bulbs, I actually have 5000k CBI bulbs will be installed once my custom shrouds are finished. I will go into more detail about the mounting when I post more pictures.
Here are some pics taken with my Iphone, better camera will be used next time.

Car is about 40ft from the wall, I am standing behind the car.



Front of the car within 15 feet



I still have to work on the aiming, but the cutoff is colorful and razor sharp.



Let me know what you guys think.

UPDATE 6/18/13!!

Sorry for the wait, this is a much overdue write-up.

My goals were to develop a design that would not be overly complicated, work with all the factory components and provide the best possible light output. I already tried different housings with a PNP HID kit and it certainly “looked” brighter but offered no real gain in usable light output. After much research I determined that a projector would provide the additional output I was trying to achieve. I only wanted a low-beam projector instead of a Bi-Xenon projector. Figured if my low beams were bright enough, I would never need upgraded high beams. So I contacted The Retrofit Source and the parts list started to grow. WOW anyone that is in the market for any HID equipment or parts please do yourself a favor and use these guys. Incredible knowledge of everything regarding HID or retrofitting, and their product selection is top notch (no EBay garbage here).
The parts list:
RX330 AFS projectors with clear lens
50-watt Elite Morimoto D2S kit
Osram CBI Bulbs

The headlights I thought were always ugly, starting point with the headlight surround already off.



Next removed the 4 screws to pull the headlight out.



This was the point where I wanted to maintain as much of the factory system as possible. Utilizing the factory bucket, I wanted to develop a mounting plate that would hold the projector in the factory location. Working with my soon to be father in law, which is a mechanical engineer, he took some measures and started entering figures into his CAD program. We decided a polycarbonate material would be the best material to work with. It would offer enough rigidity, easy to cut, and low cost. This is what he came up with:





Using a 3/8’s sheet of clear polycarbonate, he was able to cut a hole that was exactly the shape of the body of the projector. Then cut the surrounding template to match the exactly shape of the bucket. Once the template was finished I moved on to modifying the buck, had to open the back up some.





Opening up the bucket allowed the projector to slide through. So after I painted the template with black paint this is how the template attaches to the projector.









After finishing this part the real fun part began. Pig-backing off of a couple thread on this site and HIDplanet, I wanted to make a cover for the projectors. I wanted something that contoured to the body of the projector instead of using a 4x6 design similar to the Blackbird Solution’s covers. After going through multiple materials that would either cause too many bubbles or too little detail finally were able to find the proper material and thickness. I vacuum formed the covers that resulted in this:





And the final version of the cover:



The finished product:





I should be able to have more photo of them installed on the car in a couple weeks. Questions, comments, and thoughts are welcome. Let me know what you guys think.

 

Very nice man! I wish I had the resources to put something like this in my TA

 

Output looks great. Any pics of the actual retro?

 

Yes I don't have time to go through the whole process but I will have time in a couple weeks.

 

Very nice, I love that cutoff!

I retrofitted some Audi A4 (Valeo) projectors in my car. They are pretty good, but definitely do not have the nicer cutoff and light output as others. I plan to pull them off and install some FX-R projectors someday.



And I never really installed a good looking shroud. This was done very quickly and cheap.


Not really a good shot, because the car is so close to the wall. You can't really see a cutoff good until its further away.

 

What's up with that glare above the cutoff? I'd like to see some pics of the retrofit and how you managed to fit that big projector in there.

 

Typically, any glare above the cutoff is for street sign illumination.

 

Nice!!! How much did this cost you total compared to the BLS kit?

 

Got everything from The Retro Source. Absolutely the best guys to deal with trust me go to them. the parts list:
Brand new RX330 AFS projectors- $190
Moromito 50watt D2S Elite Kit-$150
Mounting polycarbonate, screws and Misc.-$30
Total $370
Then figure if you want the upgraded brightest bulbs another $180 for the CBI bulbs.(pictures are only the moromito bulbs)

 

Ill answer that for him
its the foglamps

I thought the same until I looked at next pic.

 

good prices
almost makes me wonder why Ive been collecting all these projectors.

Buddy at the body shop gave me G35 headlamp assemblies with a couple of broken tabs.
Plus Ive got tons of loose projectors.
I did my 96 Aurora now need to move on to my 97 Bird.
got any pics of the back side and mounting?
BTW nice cutoff

 

The "blocks" above the cut-off are from the "squirrel finders". Basically, its a small slit/hole in the projector's cut-off shield to let some light escape to help light up signs. Many OEM projectors have that. Some people cover them up, some people leave them.

 

I've added this to the Lighting FAQ:
https://ls1tech.com/forums/appearance-detailing/710357-lighting-faq.html

Also here is your the corresponding thread on HID Planet:
http://www.hidplanet.com/forums/show...rs-retro-on-TA.

 

Hollo- How did you make your shrouds? i'm assuming vacum former? If you have any pictures of them I would be interested to see them.

VIP- thanks. I should be able to have the full write up after the 2nd week in July.

 

Write up added to the 1st post.

 

Pretty impressive man

 

Very impressive!

 

Nice write-up. How did you seal the back of the projector though?

 

I will be sending out the projectors to get tuned with the covers on, once that is complete I will be sealing the entire projector.

 

How do you plan on sealing the back.? I think you should vacuum form a rear cover too.