Quad Bi-Xenon projector retrofit setup

Ok, Ive been buying parts for this project for some time and to my knowledge, no on else has done this before to this degree.

So I am doing not two but 4 projectors in my headlights.

There are two e55 3" projectors going to be retrofitted where the normal headlight bulbs are at.

There will be two e46 2.5" projectors going in the turn bulb side.

Both sets of projectors will have the Gatling Gun shrouds over them.

The base of all four shrouds will have 120-125mm CCFL rings in them so the crown of the shrouds "vents" will still display light also.

There are four ballast but I already have two on my truck so only two are in the pics. There will be four D2S 6000k bulbs being used.

The bottom of the inner headlight measures about 17.5" so there will be one amber LED every inch across the bottom. These will be the parking lights and turn signals as the e46 projectors will displace that bulb.

Also, you can see there are chrome domed retainers used to mount the LEDs and for some nice decor.

The amber LEDs are 5mm, 20000 mcd and 30 degree viewing angle.

Lastly, the headlight will be paint matched using Mopar paint special ordered from the dealer.

Cost for all of this material plus new headlights? You dont wanna know.

Anywho.....here are some pics.....and as always, there are pics in the linked gallery in my sig.

Over all pic



All my LEDs



My four D2S 6000k bulbs



Four D2S adapters



The 5mm LED retainers



The 5mm LED retainers and 4 Gatling Gun chrome shrouds



More pics of the shrouds



Two e55 3" projectors



Two e46 2.5" projectors



Two of four HID ballast



Two rattle cans of Mopar paint

Wow,that looks like a huge ,labor intensive process.Lots of work there.it looks good...and complicated.

OH PIECE OF CAKE.....NOT!!!!

What the heck are they for?

dodge_cowboy2004 wrote:

OH PIECE OF CAKE.....NOT!!!!

What the heck are they for?

They are for headlights..........DUH.......... LOL

Seriously though, HIDs are supposed to be in projectors and not regular headlight bowls.

this is going to be epic weed. i wish i were closer so i could help out

well i knew that...but i didnt know if they are for the STOCK lights or not.

Yeah bro, stock HLs. They just will be modified to fit these projectors. Im in the middle of making some plates like the Jimmy Jammers right now but I need to get back to this and get some progress made.

But hell, Ive got new shocks and 3" springs waiting in the living room also. I need more daylight.

looks good so far

My feelings at this point...........Im not worried about them not working. I have tested my bulbs and ballast already in the individual projectors.

My thing is doing the cutting and checking everything 2 and 3 times before I do it. As you know, if you cut too much you are screwed. And worknig with a dremel at very high RPMs plus a diamond circular plade or sanding drum, it doesnt take much to go too far.

Everythnig requires constant fitting and re-fitting to see where I am at. The main light bowls are tricky because they need to be generaly aimed in the right direction so they can be accurate aligned later on.

The turn signal side will be even more trick because the shroud will need to be cut to match the curvature of the sides and at $50 a set for shrouds, you dont want to get it wrong.

Anyway, here are some more pics.

those are massive. are you going to paint all of the chrome black or leave it

hey WEED....are you still useing the amber lens? The reason I ask is b/c I deleted mine. I found out that body filler wouldnt stay...I had to back it up with alittle bit of fiberglass mate and resin on the back side.

nevermind to my previous question i remebered where you said you were going to color match

Oklahemi wrote:

nevermind to my previous question i remebered where you said you were going to color match

Yep, already got the paint from the dealership. I just hope it comes out PERFECT because I will be mad if it doesnt. ;-)

dodge_cowboy2004 wrote:

hey WEED....are you still useing the amber lens? The reason I ask is b/c I deleted mine. I found out that body filler wouldnt stay...I had to back it up with alittle bit of fiberglass mate and resin on the back side.

Because of the small holes and smooth surfaces, I had kinda thought it wouldnt stick. Im glad you brought that up. I wonder if there is something more creative I can do with the existing holes or would filling them still be best....hmmm........

I'l take a pic of mine cover'd later on today.

Cool. I guess I will do like my double DIN conversion and put some ABS plastic on the back and then fill in the holes.

I admit Ive been goofing off a bit. I got the new Halo ODST and have been playing it. Really good game BTW. But I want these lights done for the G2G so its time to get back to work....LOL

Here are some more pics. Because I am using the e46 2.5" projectors for extra high beams, I had to modify the plate for the cutoff line. Without modification it will only act as a low beam with a "z" type cut off. Now it will look allow more light out and up as a high beam would normally do.

The other pics are just to give an idea of where I am and how it will look. The main 3" projector and shrouds are completed and installed. The 2.5" will be completed today I hope.

so the LEDs around the bottom are going to be for turn signals?

dodge_cowboy2004 wrote:

so the LEDs around the bottom are going to be for turn signals?

Exactly.

here is the pics I promised.

That looks good. I like that and will fill mine in.

I need to get back to this project. I spent last weekend re-doing my front lift and not have to do 1" blocks on the rear.

hows it going on the lights weed?