Gen 2 DIY: Bake, Open, Paint, Install HID Projectors, Profit?

Prime Jan 29, 2017

  1. Prime

    Prime Some Kind of In Charge? Admin

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    It's that time again boys and girls. More HID madness!

    Most of the setup I repeated from This thread about my 1.5 headlight build. But some things are different.

    Mainly some upgraded equipment, since things have changed in 4 years, simpler paint scheme, and some design differences with the 2nd gen headlights.

    Also, these aren't for me. I'm building them for JeffPro4x. I'll make changes when I build mine later this year. And I'll post those here.

    A few notes on disassembly. There are 4 torx screws, one in each corner, that have to be removed from the back of the headlight before baking. Just as before, make sure to remove all bulbs, rubber grommets, sockets, etc from the lights before baking.

    Remove top rack in oven, heat to 215 degrees F, foil on the bottom rack.

    [​IMG]

    While thats going, get yourself a clean work area and some tools. You'll want gloves, since the headlight will be hot when it comes out. A junky flat head for starting the opening process and a razor knife for cutting the glue as it stretches out of the gap.

    [​IMG]

    The glue on the 2nd gens is no joke. I had to let this headlight sit in the over for almost 30 minutes before I could even begin to pull it apart. Start on the edge that has no clips, use that flathead screwdriver to start a prying spot, then pull. I used the razor knife to cut the glue that was stretching as it came apart.

    One lens removed.

    [​IMG]

    Repeat for other side.

    Now to remove the reflector there are two ball clips at the top of the light. Simply pull and it will pop loose. Then take a 1/4" socket and run the adjustment screw all the way out.

    [​IMG]

    You'll see on the back of the reflector that we have some clips that hold the bulb bowl in place. Bend those out, pull it from the front and toss it.

    Enter the DREMEL!

    I was in an hurry, so I didn't take a lot of pictures here. But I will when I build my own lights. I had to open up the hole by almost a half an inch and cut the back part of old bulb holder to get enough threads to mount the projector. There is NOT a lot of material left to hold this thing in place. So it'll be crucial to reinforce with epoxy/JB weld to ensure that they don't go anywhere.

    [​IMG] [​IMG]

    [​IMG]

    This is the initial test fit. The shroud needs to be trimmed a tiny bit at the top so it can sit flat. but that aside, these are going to be badass.

    [​IMG]

    It's time to prep everything for paint. So that's coming up next.

    ______________________________

    This is the longest part of the process. Paint. Sanding, painting, waiting, painting, waiting, touching up, waiting. But, we're making progress. Since it's been cold and shiatty here, I've been painting in the garage. With the parts in boxes. It's especially frustrating because I can't hit all the different angles I need to for good coverage, but I'm making it work.

    I mentioned that the shrouds had to be clearenced a bit for the reflector. And I wasn't kidding. A bit.

    [​IMG]

    That's it. There's no other points of contact for the shrouds.

    So I started prep for one of the trim pieces.
    [​IMG]

    [​IMG]

    I'm trying this two ways. This one I masked off the turn signal so that it stayed chrome. On the other I am shooting the entire thing black, and then the cone for the turn signal will get a reflective coating inside it.

    Shot the first one with primer and flat black.
    [​IMG]

    The primer on the other one is drying as I type this.

    In the mean time, this is finished.
    [​IMG]

    [​IMG]

    And I did a final fit assembly to check my clearances.
    [​IMG]

    Then disassembled one last time for some touch up on the black. Which is drying now. As soon as that's done, I'll be ready for final mounting and securing of the projector in the reflector and after that It's time to finish and painting the shrouds and get them epoxied into place.
     
    Last edited: Sep 6, 2017
  2. Prime

    Prime Some Kind of In Charge? Admin

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    Reserved.
     
  3. Prime

    Prime Some Kind of In Charge? Admin

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    Also Reserved.
     
  4. Prime

    Prime Some Kind of In Charge? Admin

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    And another one. Why not.
     
  5. Prime

    Prime Some Kind of In Charge? Admin

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    One more for good measure.
     
    Last edited by a moderator: Jan 30, 2017
  6. jg8992

    jg8992 Hi, my name is Brandon Supporting Member

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    Much excite.

    Sent from your mom's house
     
  7. JeffPro4x

    JeffPro4x Titan Swapped / SAS'd Moderator Supporting Member

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    Yay!

    sent from a crawlspace...
     
  8. caseycamby

    caseycamby Suspension Lift

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    That shroud looks awesome sitting in there
     
  9. emtmark

    emtmark Wheeling

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    I want to do so much this is now on my list of stuff to do, still need to do the damn locker mod.....stomp stomp stomp


    Sent from my iPhone using Tapatalk
     
  10. JeffPro4x

    JeffPro4x Titan Swapped / SAS'd Moderator Supporting Member

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    [​IMG]

    sent from a crawlspace...
     
  11. Prime

    Prime Some Kind of In Charge? Admin

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    Yes. I'll take some pictures tonight.
     
  12. JeffPro4x

    JeffPro4x Titan Swapped / SAS'd Moderator Supporting Member

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    My friend thanks you.

    sent from a crawlspace...
     
  13. Muadeeb

    Muadeeb Bastard Admin from Hell Admin

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    We want pics of the lights, not of your kids or anything else, btw.
     
  14. Prime

    Prime Some Kind of In Charge? Admin

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    Ugh. Fine.
     
  15. Prime

    Prime Some Kind of In Charge? Admin

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    Updated OP with current progress pictures.

    Jeff, I owe you a new headlight. heh. I was experimenting on ways to tint the turn signal area of the lens since it's all one big piece of plastic.

    So I did this:
    [​IMG]

    And sprayed it with some of the tinting spray I used on the corner reflectors, which came out awesome btw. This, however, did not. It was a complete fail. It's hideous and just bad all around. Best of all, I can't figure out how to get it off. I'll try some actual paint remover next, but if that doesn't do it (or if it ufcks up the lens), I'll pick one up off of eBay and use the lens from that.
     
    Last edited: Sep 6, 2017
  16. Rhaas

    Rhaas Need Bigger Tires Supporting Member

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    Hey prime I gotta ask. What projectors did you use on the gen 1.5 retrofit? Cause on mine, I used the Morimoto FXR projectors. And lets just say I hate them. They are so big and bulky and because of that they are impossible to fit and align correctly in the small headlights of the gen 1.5. Im thinking about just completely restarting. Buying new headlights, projectors, shrouds, and halos. But this time using the new Morimoto mini D2S 4.0 as the projector since its smaller. But i want to be sure that it will fit like your retrofit did on the gen 1.5, easy and simple.
     
  17. JeffPro4x

    JeffPro4x Titan Swapped / SAS'd Moderator Supporting Member

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    Whoops. LOL. No worries.

    sent from a crawlspace...
     
  18. Prime

    Prime Some Kind of In Charge? Admin

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    My old setup was the mini D2S 2.0. I will tell you that the 4.0s are much bigger and better built. The 2.0s kind of looked like a toy in comparison.
     
  19. JeffPro4x

    JeffPro4x Titan Swapped / SAS'd Moderator Supporting Member

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    Here is a link to the kit we're using for my headlights, if anyone is interested. With Bullet shrouds, 35w ballasts and 4500 bulbs.

    sent from a crawlspace...
     
  20. jg8992

    jg8992 Hi, my name is Brandon Supporting Member

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    No halos right?

    Sent from your mom's house
     
  21. Prime

    Prime Some Kind of In Charge? Admin

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    No halos on this setup.
     
  22. jg8992

    jg8992 Hi, my name is Brandon Supporting Member

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    Thought so

    Sent from your mom's house
     
  23. JeffPro4x

    JeffPro4x Titan Swapped / SAS'd Moderator Supporting Member

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    No. Halos are lame.

    sent from a crawlspace...
     
  24. Fromfrontier2Xterra

    Fromfrontier2Xterra I spend more money on comic books than my X Super Moderator Supporting Member

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    You're lame!
     
  25. Fromfrontier2Xterra

    Fromfrontier2Xterra I spend more money on comic books than my X Super Moderator Supporting Member

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    Build looks awesome so far.
     
  26. Rhaas

    Rhaas Need Bigger Tires Supporting Member

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    Ok cool and you just had to cut the hole a little bit bigger for the bracket to fit. Other than that you had no issues with the projector hitting the plastic lens or anything?
     
  27. Rhaas

    Rhaas Need Bigger Tires Supporting Member

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    Halos dignify you are a true man ready for anything life throws at you man!!!
     
  28. Prime

    Prime Some Kind of In Charge? Admin

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    Not a bit.
     
  29. GPD605X

    GPD605X Lockers Installed Founding Member

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    SUB'D. These are going to look awesome!
     
  30. civicjoe

    civicjoe lone wolf mod Super Moderator Founding Member

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    This is sweet dude, I totally need mine done, just don't want to pony out the cash lol
     
  31. emtmark

    emtmark Wheeling

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    I'm with joe lol


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  32. Rhaas

    Rhaas Need Bigger Tires Supporting Member

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    It's worth every damn penny though!!!
     
  33. maillet282

    maillet282 Suspension Lift Supporting Member

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    Linked this how-to to the list of how to and DIY
     
  34. civicjoe

    civicjoe lone wolf mod Super Moderator Founding Member

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    is it though when, the x isn't my DD anymore
     
  35. Rhaas

    Rhaas Need Bigger Tires Supporting Member

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    Absolutely. No question about it!!
     
  36. JeffPro4x

    JeffPro4x Titan Swapped / SAS'd Moderator Supporting Member

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    sent from a crawlspace...
     
  37. Prime

    Prime Some Kind of In Charge? Admin

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    No. Been dealing with a lot of shiat this past week. Haven't had time to mess with them. I'll get back out there this week.
     
  38. jg8992

    jg8992 Hi, my name is Brandon Supporting Member

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    Get your power back online?

    Sent from your mom's house
     
  39. JeffPro4x

    JeffPro4x Titan Swapped / SAS'd Moderator Supporting Member

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    Well, poop. Totally forgot about that. Sorry.

    sent from a crawlspace...
     
  40. Prime

    Prime Some Kind of In Charge? Admin

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    This bezel is finished.

    [​IMG]

    The reflective spray in the turn signals is gonna be legit. Picture with flash for illustration.

    [​IMG]
     

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