Bixenon Projector retrofit - Ford Powerstroke Diesel Forum

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post #1 of 44 Old 12-29-2009, 02:23 PM Thread Starter
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Bixenon Projector retrofit

Hey guys, I was sick of the crappy stock light out put on my 04 f350, so I bought a set of pnp hid bixenon lights. I will say this, the light output was brighter then stock, but soo scattered it was almost unusable. I drove like that for a year getting flashed about every other car or so. Now I decided that enough was enough so I was looking for a cheap set of aftermarket projector headlights, well those 2 words don't go together. Anyway I found out most aftermarket "projector" headlights are halogen projectors. I search and found out it is cheaper to retrofit a set of oem bixenon projectors into our factory housing. And you get a much brighter light that is focused on the road not everywhere else. 1 huge source for hid info would hidplanet. com. Also check out theretrofitsource. com. Either way I started my project and will be well on my way once my projectors come in. Here are some pics of what I did to get ready for the projectors and as soon as I get them and the time to work on them again I will post up my progress. Thanks for looking.










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post #2 of 44 Old 01-06-2010, 09:24 PM Thread Starter
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Alright, my projectors came in today so I spent some time tonight cutting the housing to fit the projector and found it very easy, I have to aim the first light tomorrow and Ill be ready to seal up the back and make a shroud. Ill post some pics of the progress.
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post #3 of 44 Old 01-07-2010, 01:00 PM
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Keep us posted!
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post #4 of 44 Old 01-08-2010, 11:24 PM Thread Starter
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So here are the pics, all I have left is to make the shrouds and seal the lights back up!








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post #5 of 44 Old 01-09-2010, 02:03 AM
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WOW! That was a lot of work. Good job!

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post #6 of 44 Old 01-09-2010, 04:02 AM
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Would this work?

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post #7 of 44 Old 01-09-2010, 07:16 AM Thread Starter
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Im sure those would work, I would shoot them an email and make sure. Those would make the project very easy.
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post #8 of 44 Old 01-09-2010, 09:25 AM
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Great result..have additional mod pictures?
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post #9 of 44 Old 01-09-2010, 10:36 AM
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Awesome man. I'm just waiting on the funds to come in so I can pick up a set of tl's or possibly some rx350's. How did you figure out the spacing from the back of the housing to where you mounted the projector using the double nuts? Are you going to make the harness like it is shown on hidplanet using the dual relays to activate the bixenon movement?

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post #10 of 44 Old 01-09-2010, 09:43 PM Thread Starter
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For pics, thats all I have for now, but Ill take more as I go!

Quote:
Originally Posted by DieselNoob View Post
Awesome man. I'm just waiting on the funds to come in so I can pick up a set of tl's or possibly some rx350's. How did you figure out the spacing from the back of the housing to where you mounted the projector using the double nuts? Are you going to make the harness like it is shown on hidplanet using the dual relays to activate the bixenon movement?
My main reason for going the tl route, was there is plenty of room for it and it is the most highly rated bi xenon projector. For spacing, I just looked the light and tried to visualize how much it would need to go back to close the light back up. I then traced the back side of the projector onto a piece of paper and cut that into the headlight. I made sure I cut it on the smaller side and just gave it room where it needed it. After I got the depth I wanted I made sure I had enough wiggle room to adjust it in the headlight housing. I didnt bother with double nuts because its not needed. When I get the headlights perfect in the housing tomorrow night then I will epoxy everything and then the nuts will never move again. It is very easy to tighten the projector in with the 4 bolt flange the tls have. Since I am trying to bang this project out quickly I opted to buy a premade bixenon plugin harness from TRS. It was only 25 bucks and wired up really nicely. I will let you know how I like it!
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