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How To: HID Projector Retrofit (1998-200 #: 274

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Posted: Wed Nov 29th, 2017 12:48 pm

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sheltonfilms
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Originally posted on 2-17-2016:

Been wanting to do this forever but it can be expensive. I had to work overtime over the Thanksgiving holiday and that gave me an awesome paycheck. Combine that with 25% from theretrofitsource.com on Black Friday I had to pull the trigger.
Ok so here is what I got:
Mini D2S Projector X Lens (Square)Square Gatling Gun ShroudsXB35 BallastsXB 5500K D2S Bulbs9007 HarnessSquare XSB Switchback Halos (wasn't dying for them but they were on clearance).Set of EBAY clear lens headlights (98-00 factory headlights have a diffuser lens).

Process:
Here is the new headlight:

Bake at about 275 for 7 mins and pry lens off and remove old butyl.

Remove the old halogen "cap"

The the threaded shaft of the Mini D2S projector is larger than the 9007 bulb hole and is also too long to get the lock ring on. Need to take material out of the inside and cut the shaft down.

The 98-00 buckets are really deep and wide so the shroud doesn't need trimming. But due to me keeping the chrome finish on the reflector I don't want to see this black ring in the reflection of the back of the shroud/projector.

So what I did is make an aluminum plate that is bolted to the projector. Cut it so there is small gap between it and the shroud and then steelstik aluminum strips around take up the gap. Pretty much it's a shroud extension. Added foil tape to get all of the light sealed and added a grommet for the wires.

Added the switchback halo to the outside of the shroud using 26 gauge wire.

Everything looks like it would seal well except for the D2S igniter to the bulb. I looked at adding a 3" PVC pipe and a rubber cap like JP7 did on his Mazda retro (he had a straight connection). Due to my igniters being at a 90 degree angle I didn't see this as a good way to do it. Plus there is not much clearance for the pipe so the header panel and radiator support would have to be trimmed.
So I found an old grommet and cut the inside and it fit the igniter and had enough thickness to seal between it and the nut.

Here are the halos lit up with the amber turn signal:

Pictures of it lit up (without halos) and the cutoff on my neighbors house.

I sealed everything back up with new butyl. I added silicon to the hole in the back where the wires come out and also ran some around the lock ring.
I'm still in the process of aligning up everything right.
If you are familiar with the 3 adjustment/attachment posts you know that the top post is the vertical adjustment, the one on the other side is for horizontal, and the one left is the "stationary one". I say stationary because there is no 4mm hex end to change it while on the truck.
I believe the halogen bulbs in the factory buckets are setup in a more downward slope than an HID projector would be. Because of this I have to tilt the bucket up more to compensate. I ran out of adjustment so I took of the headlight and adjusted the "non adjustable" post.
This messed up my horizontal alignment and also causes my housing to stick out past the other lights like 1/2".
If I thought of this before I sealed it I would have shimmed the projector alignment in the bucket by doing something like adding layers of foil tape between the projector silcone ring and bucket at the bottom to push the projector up.
Still working this out. Once I get this figured out and my halos wired up I will post pictures.
I've been driving with them the past two days and keep making vertical adjustments until I can find a perfectly flat area with a flat wall to do a true adjustment.
If you do this don't take your maiden voyage on wet payment. You will think you just wasted your money. Something about wet asphalt just sucks up light.
Took it out today on dry roads and the results are amazing. Looks better than the Mercedes LED headlights at work. Definitely need to get the horizontal adjustment fixed. When I come up on a hill the steps are separated but as the truck levels off and cutoff is casted farther down, the steps merge into one. They need to stay the same distance apart.

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2000 XLT 2.5L A/T 2WD
Mods:
Power Windows/Locks Mirrors using OEM harness and parts
Explorer Sportrac White Face Cluster
Explorer OHC and Auto-dim Mirror
Auto Door Locks
Full HID Projector Retrofit

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Posted: Wed Nov 29th, 2017 04:29 pm

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mhoward
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Excellent write up Anthony! Maybe someday, I will do this to my truck!

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2003 Ranger Edge / Extended Cab / Flareside / 3.0L FLEX / 5r44e Auto / 2WD / 8.8 LS 4:10 / Sonic Blue Pearl

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Posted: Wed Nov 29th, 2017 05:06 pm

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JAMMAN

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I have not embraced the HID culture yet but equally thankful for the write up. I'm sure this would apply to plenty of other builds too :)

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Posted: Wed Nov 29th, 2017 05:11 pm

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sheltonfilms
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The 01 and up Rangers have a shallower housing so you have to do some more extensive fabrication to fit the projectors in. ShockerGuy did one IIRC. Had to cut a lot of material out the back to get the projector to sit further back.

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Posted: Wed Nov 29th, 2017 05:17 pm

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TheArcticWolf1911
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Dang, now I really want a set of HIDs for my truck now. Curious, do these use the same bulb size as the stock setup, or is it completely different?

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Posted: Wed Nov 29th, 2017 08:48 pm

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sheltonfilms
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Hid bulbs are different than halogen. Halogen runs off 12V and HIDs arc at 25kV and run at like 80 to 90.

It takes a ballast (like a shop light) and an ignitor (sometimes its built into the ballast and sometimes it's in the cord like mine).

You can get HID bulbs that fit your current headlight but they look like garbage because the light isn't concentrated in a projector. You get all kinds of glare and you essentially appear to have the high beams on at all times. Most of the A-hole truck guys do this.

The projector has a piece of metal that cuts off the beam and it has a step in it (higher on the right side) this is to keep the glare down for on coming traffic.

When you apply highbeams the metal cutoff is pulled away and it exposes the full beam.

Unlike Ranger bulbs that have a high and low filament, HIDs are just single. So nothing changes on the bulb when you switch between high and low just the movement of the cutoff shield.

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Posted: Wed Nov 29th, 2017 09:06 pm

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TheArcticWolf1911
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Hmm. I see. I was kind of hoping to be able to try this LED headlight kit I have in a set of projectors to see if they're any good. They suck in a big way in reflector housings.

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1999 Ford Ranger XLT - 3.0 V6 4x4 - Loaded (Totaled) 143k. Rest in Peace, Gold Dust.

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Posted: Wed Nov 29th, 2017 11:51 pm

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Undrstm8ed
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Nice setup and work..

If I wasnt afraid of more 1/4 mile water crossings saturating a set and throwing $300-500 away I'd do these myself but I don't trust they'd survive many water crossings unless completely or hermetically sealed for that matter.

And some times, just some times I like being noticed as some older guy in an old ass pick up truck unless you give me a reason to hit my ALL-ON switch and light your ass up like a scene from close & counters of another kind lmao. Be worse once I put the other lights in and on by spring.

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Posted: Thu Nov 30th, 2017 12:37 pm

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It's an awesome mod. My headlights have the FX-R 3" projectors in them, and the fogs have thee D2S projectors. Switchback halo's wired to the turn, I'm very happy with the light I can throw now.

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Posted: Mon Jan 8th, 2018 12:08 pm

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Scrambler82
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I have tried to look into Projector Headlight four or five times and get more confused every time I try.
Maybe someone needs to make a kit with everything you need, GOOD Parts, good epoxy, just everything right !

HIDs are in my opinion the way to go... in a few years LEDs will be perfected for Headlights and then an upgrade needed.
Make sure you figure in the LED option, in your plans for the Projectors... just in case.

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2003 EDGE, Std Cab, Steppie, E4 Red, 5sp, 4x
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Hurst Shifter
Mod'd Backrack to fit Steppie
Front and Rear Bumpers by Custom 4x4 Fabrication, OK; now Mike's Welding and Fabrication.
Working on more Mods, just need more time, longer days would work !

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Posted: Wed Apr 18th, 2018 09:37 pm

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Scrambler82
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Ordinary Biker wrote:
My headlights have the FX-R 3" projectors in them, and the fogs have thee D2S projectors. Switchback halo's wired to the turn.

--------------------------------------------

OB,
How do the FX-R 3" Projectors compare to the 3" D2S's ?
How do the D2S work out in the Fog Lights ?
Seems like a lot of light for Fog Light.
Do you run the Fogs on with the headlights ?

thx

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Posted: Wed Apr 18th, 2018 10:09 pm

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Scrambler82
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sheltonfilms,

Why the square projectors instead of round ?

Are the patterns different... better ?

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Posted: Wed Apr 18th, 2018 10:12 pm

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sheltonfilms
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Scrambler82 wrote:
sheltonfilms,

Why the square projectors instead of round ?

Are the patterns different... better ?
Just wanted something different. Plus I think the square halos were on clearance at the time.

No difference in output.

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Posted: Wed Apr 18th, 2018 10:23 pm

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Scrambler82
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sheltonfilms wrote:
Scrambler82 wrote:

sheltonfilms,

Why the square projectors instead of round ?

Are the patterns different... better ?
Just wanted something different. Plus I think the square halos were on clearance at the time.

No difference in output.
OK on the looking different !
I looked at the D2s squares too, thought on it and I am going with the D2S 4.0s.

I don't feel competent enough for this install without a jig of some sort, so I am looking for a shop around me in SoCal to do the job.
I am having trouble getting responses from shops suggested by The Retrofit Source, time will tell !

I get impatient once I make a decision !

ltr

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Posted: Thu May 3rd, 2018 01:38 am

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buggman

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I really need to get into headlight retrofits!

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Posted: Thu May 3rd, 2018 12:50 pm

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Scrambler82
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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

Last edited on Thu May 3rd, 2018 12:56 pm by Scrambler82

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Posted: Fri May 4th, 2018 01:35 am

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buggman

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Scrambler82 wrote:
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 :-(

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1996 XLT Supercab 4.0L 4x4
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Posted: Fri May 4th, 2018 06:27 am

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Scrambler82
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buggman wrote:

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.
I'm with ya note Jig, not sure how mine will work out, got the Headlight Pieces yesterday, the Projectors, (smaller than expected, good...), Harnessing, Halos, Toroids, and little things. I need to locate a pipe with a 3.5" ID, may have to either sand the hell out of the ID of a larger piece of pipe or have some machined, need to check out standard pipe ID but want a thick wall. Not sure what a 4" PVC Pipe has for an ID but since I plan a Plate on the back to mount the Projector to I guess the ID need just enough room for the Projector to slip in.

Also, thinking about the eBay Jig,

https://www.ebay.com/itm/Car-Headlight-Retrofit-Mounting-Moulds-Plate-Fit-Q5-E5-Hella-Projector-Lens-Trig/292422326238?hash=item4415ba97de:g:XXoAAOSw38BaYh5Q&vxp=mtr ,

making a new center pin/standard Drilling Bushing, that would at least center things up.
Still thinking on a complete rear mounting system but as you said I am not sure about the PVC/ABS Plastic adhering to the housing... hoping for JB Weld to do the bonding.

Jig Pic -

No pictures of the packaging because the package was picked up on an out bound trip with the Wife driving and I had to look but the packaging was a cardboard box with some, and I do mean some packaging peanuts, that was all. The individual component boxes were the main protection during shipping.

All of the parts look ok; more measuring will take place tomorrow after the Brush Hog is attached to the tractor and the lower 10 (LoL) are cleaned up of Brush.

Last edited on Fri May 4th, 2018 06:32 am by Scrambler82

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Posted: Thu Apr 11th, 2019 02:12 pm

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Scrambler82
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sheltonfilms,

If I didn't say so before, great write up !

I wish the '03 Headlight Housings were as deep as the '00 back.

I need a large hole inline.

I still haven't finished mine, too many things on the Honey-Do List... I'm not getting any younger !

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