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Discussion Starter · #1 ·
Well after having many sets of OEM HIDS (about 5 sets), and about 3 sets of OEM GLI Headlights, OEM HID reps, and lastly a set of OEM Jetta headlights without fogs, I figured its time for me to take a stab at making my own headlights

Specs of my setup:
-FX-R Bi-Xenon Projectors with clear lenses
-Matsu****a Gen 3 ballasts
-Morimoto 4300K bulbs
-E55-R shrouds
I have everything but the projectors themselves. They were backordered when I ordered them and The Retrofit Source is expecting them this Thursday, and offered to get them to me in my hands before the weekend, free of charge.
Awesome customer service from Matt @ The Retrofit Source http://****************.com/smile/emthup.gif http://****************.com/smile/emthup.gif
On to the pictures.... I am taking my time with this since I want this to be completely OEM looking once finished. I am NOT painting the inside black, or any color for that matter. I will neatly try to get everything arranged that I retain all the chrome.

First I preheated the oven to 200 degrees. I later found that to be a little on the low side and bumped it up to 225 degrees.

Take an almost brand new set of GLI headlights and get them ready

Remove all the metal clips that hold the lens to the rest of the light, the two rubber vents, all bulbs, all covers





Once you have everything off this is what your lights will look like

I put all the parts I took off in a plastic zip lock bag so I wouldnt loose any of the pieces

Put your light on a cookie sheet to prevent melting the bottom of the light on the oven rack

Get your timing device ready and put the light in the oven


Once its time, remove the light from the oven. Use oven mits, I ended up learning the hard way. Even though its in there for 1:30 it still gets pretty damn warm.


Grab your tool of choice to pry the case open with, in my case I used a scraper, and it turned out to work just fine.

After some prying and heating for an additional 30 seconds, and prying and heating I finally got them to seperate. Keep in mind to start on the bottom of the light since you cant see that side once its installed.
I also took my time doing this very carefully because once I am done with these lights I want them to look like they were never opened.

Finally seperated, might wanna keep a knife handy as the urethane glue used on these lights is tough even when warm, always easier to just cut it than tug on the cover and break it.

Do the same with the second light


Now youve got the two headlights seperated, now its time to remove the inner chrome part from the rest of the headlight. There are two "balljoint" type of mechanisms by either of the levelers, just give it a good tug and they pop right out. You can see them in these pictures where they pop in and such.


Since I want to reglue the lights and not reuse the old urethane glue on the lights I decided to clean as much of the glue off of the lights as I can.
Before:

After:

Took the good part of about 2 hours just to get it out of the back of the light, still have the 2 lenses and the back of the other one to remove the glue from

I'll have more pictures later tonight or tomorrow of the rest of the stuff I am using for the retrofit. http://****************.com/smile/emthup.gif
Day 2
Started taking the glue off of the lenses. First I removed the black housing from inside the lense removing 4xT-15 Torx screws, you can see them in the picture the little gray things.

Seperated from the lense


Glue on the lense before:


Clean of glue after:


Day 3 (like a week later)
Well finally got everything in today and got working on one of the lights. Almost done with the drivers side light but I want to be 100% sure that its aligned correctly before I start sealing stuff up so I have to wait till tomorrow to get it on the car.
I first taped up all the chrome to ensure I didnt scratch it.

I then made a paper template of the projector and what I was to cut out of the lights.

Test fit the paper and if needed make more cuts till its snug

Transfer it to cardboard since its sturdier.

Cut it out like shown to make it easier to handle and align.

Trace it on the tape

Cut it out and mount the projector. I got a little carried away when I was cutting and cut a decent amount off. Not a big deal because it wont be visible with the shroud on.

My jerry-rigged setup just to test out how the projector is placed in respect to the inner headlight bezel.

Cutoff

What one of the lights looks semi finished.




Loosely put in the housing as a visual. Everything is still dirty and has to be cleaned up tomorrow


Here are some more pictures of the lights. I finished up the other one earlier today before class. They are both done just waiting on the silicone to dry.

Mounted the light on the car just to make sure the beam was level and not twisted. The blue tape marks the cutoff of the stock halogen lights so I knew if the projectors were rotated or not.


Since people dont know what I mean about how the projectors are mounted to the oem headlights heres a few pictures.


All siliconed up and drying






Modified by Mr. Appleton at 3:33 PM 2-3-2010
 

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Re: My stab at retrofitting (dief)

Hey Mike I thought you just got some new headlights?????
 

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more please, I hate progress threads...just make it when you are all finished and reward each new page with new pics!
 

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Re: My stab at retrofitting (b2)

Nice Work Appledick http://****************.com/smile/emthup.gif http://****************.com/smile/emthup.gif http://****************.com/smile/emthup.gif
 

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Re: (onepointeightdub)

sweet im right in the middle of mine too. ill be done tomorrow afternoon. http://****************.com/smile/emthup.gif
lmk if you have any tips on lens polishing bc I need to polish the crap out of my lenses they are really hazy.
 

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Re: (formerly silveratljetta)

Looking good. Gonna follow this. I've wanted to try a set myself for some time. Maybe this'll help me nut up.
 

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Re: (formerly silveratljetta)

watching!
 

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Discussion Starter · #17 ·
Re: (idwurks)

Quote, originally posted by b2 »
Hey Mike I thought you just got some new headlights?????

I did, but theres always room for a change. Kinda jealous of the hids on my moms Lexus RX330, plus after always been wanting to do a retrofit, I finally bit the bullet.
Quote, originally posted by Colin. »
more please, I hate progress threads...just make it when you are all finished and reward each new page with new pics!

I was thinking about that, but usually towards the end I get lazy and end up not making a thread, at least this way I kinda have to finish posting in here now

Quote, originally posted by 01GTiVRSICK »
Looking like work is getting done. http://****************.com/smile/emthup.gif

http://****************.com/smile/emthup.gif

Quote, originally posted by .:Rudeboy »
Nice Work Appledick http://****************.com/smile/emthup.gif http://****************.com/smile/emthup.gif http://****************.com/smile/emthup.gif

Thanks Rudi http://****************.com/smile/emthup.gif
Quote, originally posted by Tj_gti »
nice write up so far

Thanks
Quote, originally posted by j. Kush »
Watching. I love retrofit threads.


Quote, originally posted by onepointeightdub »
More pics of the stove

Its dirty, kinda embarrasing.

Quote, originally posted by jimothy cricket »
You have some very cute kitchen decor Mike

Knowing you this should be a pretty boss retrofit. http://****************.com/smile/emthup.gif

Quiet you, Im in the process of slowly changing stuff up in the kitchen.
Quote, originally posted by formerly silveratljetta »
sweet im right in the middle of mine too. ill be done tomorrow afternoon. http://****************.com/smile/emthup.gif
lmk if you have any tips on lens polishing bc I need to polish the crap out of my lenses they are really hazy.

Nice
For the polishing I would say, start at a coarse grit somewhere in the neighborhood of 400 and work your way up to about 2000 grit. Hit it with a polisher, or polish by hand if your up for a lot of polishing. Should get you some crystal clear lenses. http://****************.com/smile/emthup.gif
Quote, originally posted by FigureFive »
Looking good. Gonna follow this. I've wanted to try a set myself for some time. Maybe this'll help me nut up.

I was the same way, most of the time I let the OEM HIDs cut it
I finally gave up on buying OEM HIDs and figured to try a retrofit. Should be pretty damn nice in the end and the light output will crush any set of OEM HIDs. Sucks that the projector is so small on them.
Quote, originally posted by sbuogr »
watching!


Quote, originally posted by YooFatBoy »
hmm interesting

Of course

Quote, originally posted by KazzThemurse »
watching


Quote, originally posted by idwurks »
Good on you to keep the chrome http://****************.com/smile/emthup.gif

Yea, I couldnt do them any other way. I absolutely hate the fact that people paint them black after retrofitting to hide all the imperfections. I'm gonna be very careful so I dont have to do that.
 
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