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-7x6 Housings (Housings with plastic lenses are less likely to break when taking apart)
7X6 H6052/H6054 Sealed Beam Rectangular Black Projector Headlights Replacement https://www.amazon.com/dp/B009OSLC8I..._2zcVub146M685
-HID Kit (This kit comes with bulbs that don't fit the projectors, I didn't realize it until after I ordered it)
Zenex HID Conversion Kit H4/9003/HB2 4300K Hi/Lo Dual Xenon (OEM White) https://www.amazon.com/dp/B005QRQMKO..._jzcVub0YG0G38
1. Remove the lenses from the housings by putting them in the oven at 230-240° for around 10 minutes or until you can get them apart. Be extremely careful if using glass lenses they break easily.
2. Remove all bulb mounting parts and whatever fake projector is inside the housing.
3. I used a jigsaw to cut out the bulb mounting surface of the housing. Then sanded down anything that was left.
I made this out of an old broom stick for the sanding
4. Cut about half an inch off the bottom of the drop in ashtray (I used a Dremel with a cutoff wheel) to fit in back of the housing. Sand it down on the sides a little at a time until it can fit flush with the back of the hole.
Use a hole saw to cut out the middle.
5. Fit the projector in the housing. I had to file quite a bit off the bottom corners to get it to fit right.
6. Fit the shroud. I had to cut around 1/4" off to get them to fit. I used the Dremel for this also.
Use pliers to pull off melted plastic
7. Test fit everything
8. Epoxy the back piece in
9. Paint
10. Install projector and make sure it's level.
11. Install the shroud with epoxy. Double check that everything fits first
12. Install lens. I used RTV then went around the outside with epoxy.
I had to get creative with the clamps
13. Cut to fit the housings. I didnt have a hole saw that could cut metal so I had to use tin snips and a Sawzall then hammer everything out
14. Install everything aim your lights and enjoy!
My old lights(Autopal e-codes with 55/60 and Putco harness) vs the HIDs
$12 amazon bulbs
Morimoto xb35s
If anyone has any questions let me know.
Last edited by DenimDean; Jan 22, 2015 at 12:27 AM.
I've been thinking about going with the 55w setup in mine. I just can't decide what protector to go with. I definitely don't want to have to cut into my headlight ports like you had to, so one of my only options might be these here:
I've been thinking about going with the 55w setup in mine. I just can't decide what protector to go with. I definitely don't want to have to cut into my headlight ports like you had to, so one of my only options might be these here:
I have some morimoto xb35 4300k bulbs on the way so I will do another comparison when I get them installed.
Nice job and good choice on the bulbs I'll be surprised if you don't see a difference. If you get any moisture in the housing the goretex patches that TRS sells can help keep them dry.
Originally Posted by thatXJguy
I've been thinking about going with the 55w setup in mine. I just can't decide what protector to go with. I definitely don't want to have to cut into my headlight ports like you had to, so one of my only options might be these
Bleh... ugly I know, they stick out past the grille. :/.
Glad you said it first. Why on earth would you want those over drilling a hole in the header panel? I wouldn't run 55w bulb in anything smaller than a FXR projector which is what I want for my next hid upgrade.
Nice job and good choice on the bulbs I'll be surprised if you don't see a difference. If you get any moisture in the housing the goretex patches that TRS sells can help keep them dry.
Thanks. I soaked them at the car wash pretty good and they didn't fog up or anything but I'll keep that in mind
Nice write up! FYI. I bought the cheapo glass 7x6 headlights off of eBay and the easiest way for me to take the lense off was to soak them in gasoline for a few days. The gasoline didn't harm the plastic or reflective coating.
Nice write-up. I have HIDs in mine with Morimotos and 4300k bulbs on 35 watt ballasts. Not sure why anyone would need to go with 55 watts. Mine are enormously bright on low, and on high they are just awesome! Plenty for any on-road driving. And for off road I have a 3000 lumen light bar on the bumper and two 1200 lumen pods on the roof rack.
Thanks guys. My morimotos came in today. I'll add pictures to the original post. I only can tell a slight difference in color and brightness(I wasn't expecting much).
Last edited by DenimDean; Jan 22, 2015 at 12:13 AM.
HID Retrofit Write-Up
