HID Projector Retrofit

[JAS6377]

Howdy, all. After rolling around as one of "those guys" (y'know, the ones with HIDs in reflector housings?) for a season, I decided it was high time I not blind people. So, I decided to do a retrofit! The idea was to get an HID projector into the light, and add LED turn signals to augment my not-so-easily-seen flush mounts. I used the Motorcycle Stage I kit from The Retrofit Source: 35W 6000k bulb, Morimoto mini D2S bi-xenon projector, and Apollo 3.0 shroud. I couldn't use the CFL ring for the vents, but oh well. I'll repurpose it somehow. I also purchased a 100 cm length of amber 5050 SMD LEDs from Super Bright LEDs to use for my turn signals, of which I only used about half. Again, oh well. I'll find a use for them.

Before I get started, big shout outs to weedahoe for helping me with all of my (sometimes silly) questions  , and Frankenbike for supplying me with a good headlight so I didn't have to chance destroying my current one. 

So, we start with the headlight:


Then remove all extras: the rubber bushings and those little plastic doohickies on the back.


I then pre-heated the oven to 200F, and baked the headlight for 10 minutes. Just enough to pull it apart. The top is a bit tricky due to the geometry, but it's not too bad if you take your time.


Wait a couple days... Get my parts...
And planning...


The LEDs on the light and soldered together with 30-gauge wire:


To get the projector to fit into the headlight, the bulb hole needs to be widened, and the plastic on the back of the hole needs to be ground down so it's flush. This allows the projector threads enough room to be fitted properly. Unfortunately, I was really intent on what I was doing, and forgot to take pictures of this process... Sorry, guys. 

But here is the projector in the assembly:


The shroud also had to be cut on the top and bottom to fit into the housing. The end result of which looks like this:


Once everything was set up, I baked it again and put it back together. Simple!


And, the turn signals, which I think turned out pretty well:


Oh, and I can't forget my helpers!




I should have enough time to get everything mounted up tomorrow after work. I'll post light output pics and whatnot tomorrow.

Thanks again to weedahoe and Frankenbike for making this project become a reality. 

[1200]

Awesome Mod!  Can't wait to see the on-bike pics.

When you were baking the light to go back together, did you have to use any sealer?  I'd be concerned about moisture finding its way into the light housing and producing that water droplet foggy look inside the light...   

[Janx101]

On the moisture thing.... I'm not sure that the standard setup (which I realise this is not!) is exactly 'sealed' completely.... Water vapour could still theoretically find its way into the housing around the bulb base.... It's tight but not hermetic!

If anything I'd want a slight airflow being possible at the back ... To allow the heat of the lit up bulb to slowly steam any droplets away and let the moist air out through the bulb area...

I would also think that the baking process is to make sure the dang front 'lens' doesn't fall off ... Rather than seal it from the elements to the N-th degree?

[JAS6377]

You're both right, actually. The stock housing really isn't completely sealed, due to the way the bulb sits. The projector has a silicon seal on it, though, so is basically is airtight after the mod. To answer your question, 1200, I didn't use any more sealant. By baking it, the sealant became goopy again, which allowed it to seal. If I were to open it a second time, I'd probably add more sealant just because I don't know how much thermal abuse that stuff can take. Which is also why I only baked at 200. I've read about people doing this at 350, but it really isn't necessary if you're quick about getting it open.

[1200]

On the moisture thing.... I'm not sure that the standard setup (which I realise this is not!) is exactly 'sealed' completely.... Water vapour could still theoretically find its way into the housing around the bulb base.... It's tight but not hermetic!

If anything I'd want a slight airflow being possible at the back ... To allow the heat of the lit up bulb to slowly steam any droplets away and let the moist air out through the bulb area...

I would also think that the baking process is to make sure the dang front 'lens' doesn't fall off ... Rather than seal it from the elements to the N-th degree?

Thanks @JAS6377.   All of your points make perfect sense.  Occasionally I do see bikes and cars with the watered lenses.  I have a Kaw with big double-buckets that I had contemplated doing this mod to but strayed away from it because of the possibility of the moisture issues. Right now they are tight as a-bug-in-the-rug!

So is there a layer of glue between the lens and the bucket that is viable to reheat for a somewhat good sealing? I guess I should ask the OP who just opened his up... I always thought there was a gasket in there. 

[JAS6377]

Yep. It's just black oxy butyl tape. Even when it's cold, it's still kind of pliable. Kind of like a hard plumber's putty, if that makes any sense.

[1200]

Yep. It's just black oxy butyl tape. Even when it's cold, it's still kind of pliable. Kind of like a hard plumber's putty, if that makes any sense.

Wonder if I can guy some of it anywhere local or online?  It would be good for other stuff also...

[JAS6377]

I know TRS sells it. I'm pretty sure you could find some on Amazon, too.

Oh, and friendly tip: TEST IT BEFORE YOU PUT IT BACK TOGETHER. I put the projector in upside down lol.

Edit: Also, as far as being airtight, it won't matter. The parking light cover has vents in it.

[radodrill]

I put in an HID projector without chopping the back of the stock reflector; I simply mounted the threaded part of the HID into the existing bulb mount.  The projector lens is a bit further forward, but you don't see anything when it's all together.  I went with a 2.5" projector and in retrospect could have gone with 3"

[weedahoe]

Looking really good. Time for some night shots

[JAS6377]

Yeah, I've been a little busy troubleshooting a tail light issue lol. I'll see if I can grab a couple shots tonight.

[JAS6377]

I completely forgot about this thread... I haven't taken pics yet because I'm ashamed of how poorly I aimed the thing. I'm currently in the process of fixing this issue. Hopefully I'll have it aimed and back together before the night ends.

[JAS6377]

Yeah, so that didn't work out. My sister is back in the hospital for her second pregnancy. But, I was able to aim everything tonight. Here are the output pics for thread closure.