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Do Not Touch The Trim!
Joined: Thu Oct 19th, 2017
Location: USA
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Buggman,
Just thinking out loud... BUT... IF you were to make a jig, that mounted using the positioning of the 9007 bulb, and would allow the drilling of the four mounting holes, that could be a seller.
The actual Jig is on eBay, except for one critical thing, the 9007 adapter; I have been told that th e9007 is the older bulb type now and there isn't an adapter for it... WTF, old bulb type !
If you were able to make a jig and a way to make the adapter, specific for the Ranger but adaptable to other vehicles it could open up a new market for you; and yes, they can be made of aluminum !
I ordered my parts, waiting for them to drive today, next I need to make a center plug used on the 9007 opening and then drill an opening in the rear of the Housings the size of the front end of the D2S's, up to the mounting plate, maybe I will use a short piece of PVC Pipe, just to clean up the opening.
Since the '03 Housings are shallow, I want to mount the Projector from the rear, allowing for easy replacement IF necessary.
I will set the new opening in the rear based on the Front end diameter of the D2S, 3.35 inches (?), 85mm, plus the thickness of a mounting plate.
The Plate may be metal, like aluminum, or even Plastic, not sure yet !
Still thinking on it but only time will tell.
Qualifier: This is my first attempt on a Projector Headlight Retrofit, over thinking here some, and I am not even sure my ideas will work out... BUT if they do it could simplify the process of cutting the Headlight Housings but not the Radiator Support or the Header Panel, those will require more cutting because the Projectors will be mounting further back.
Ltr
Can't wait to see how yours turns out! I'll definitely need some hand holding to get started myself, but I like the idea of making a drilling jig. I'm still kinda old school & make jigs for all my projects... still can't get around to building my own cnc
Not sure if abs pipe or pvc pipe would be able to adhere to the plastic of the housings, but it might be something to investigate. I think i have an old headlight from an explorer that i might do some testing on just to see what i can materials will stick to it lol. might have to order up some plastic weld epoxy or something to play with.
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1996 XLT Supercab 4.0L 4x4
Lots of Explorer parts & tons of my custom mods.