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Old 08-11-2010, 02:36 PM   #1
budahrocket
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Default Walkthrough: 02/03 Bugeye bi-xenon Projector Retrofit, no cutting

thanks to jdubya, based a lot of my project off of his thread:

http://forums.nasioc.com/forums/show....php?t=1482552

So I've wanted to do a retrofit on my bugeye for about a year now, and I have to say it went a lot smoother than I expected. However, that is not to say that you won't run into some problems. This is meant to be a complete walk-through, but some steps will vary from person to person and require some ingenuity.

I cannot be held responsible for any damage, injury, or legal matters that may arise from following this walkthrough. It is a write up that is intended to assist you on a retrofit project and serve as a guideline.



If you are mechanically inclined and are familiar with your bugeye then I say go for it! and good luck

I had a kit put together of some generic projectors that are shaped to fit into the bugeye reflector bowl without cutting, two ballasts, ballast mounts, chrome shrouds, wiring harness with relay, and angel eye inverters.

My favorite part about this retrofit was that there was no cutting of the reflector bowl or projector, the only power tool needed is a drill.



I didn't use the shrouds they came with or the angel eyes because I wanted to make a set with hella e55 shrouds, which I got on eBay for $18.



To be honest, I was a little weary of the quality but once everything was installed, the light output was amazing (hits the houses at the end of my street about 100 yards away) and the wiring could not be easier. The kit is just perfect for a retrofit in a bugeye, but I will be considering upgrading the ballasts and bulbs to a d2s connector, which I will talk about more later.

on to the retrofit:

The first step is taking the headlights off of the car. If you have the stock grill you will need to remove the middle clip and then the two side pieces with the plastic pop screws. The headlights are just three bolts on each side. Carefully slide the headlights out a couple inches and unplug the two harnesses on each side. it should look like this:



Now you will need to take apart your headlights. If you have never taken your headlights apart you can look up the koji mod for a more in-depth write-up, but its really not that bad. I use:

-a small heat gun
-flat head screwdriver
-phillips head screwdriver
-some heat resistant gloves.



The oven will also work great, but I find the heat gun easier. There are two screw on the back outside edge of the headlight that needs to come off, (jdub has a great picture pointing to these screws.) you can see one of them here to the far left



remove the two screws, turn signal light, parking light, and main light.



Now if you are using the oven, put it in for about 15 minutes on 250, and if you are using a heat gun, point at the back of the headlight housing where it meets the lens. This will heat up the silicon so you can pull the lens off.

With the flat head gently pry the lens apart from the housing. There will be some tabs that need to be pried apart first.



Anytime from now until you seal up the headlights would be a good time to clear your lenses. But for now, just set them aside, we'll get back to them later.
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Last edited by budahrocket; 08-11-2010 at 03:15 PM.
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Old 08-11-2010, 02:36 PM   #2
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Removing the Reflector Bowl:

For this all you need is a socket (I think its 8mm) and a flat head screwdriver



There are two bolts that hold the bowl in and a ball and socket joint. The two bolts are responsible for adjusting the light and will be used later to aim the projectors.

One of the bolts is just under the white plastic wheel and spins the wheel when you turn it (you can see it better in the picture above, for some reason I removed the wheel but you don't need to)



The other is behind a small rubber grommet that you will need to pop off.



Loosen these two bolts alternately as much as you can until the look like they are off. Then get your flat head and pry up the ball and socket joint, it will pop up with a little force.



The projector bowl will just lift off, be careful, and remove the two plastic pieces that the screws mate up to.

plastic piece 1:



plastic piece 2:



Put these somewhere and don't lose them.

Last edited by budahrocket; 08-11-2010 at 02:50 PM.
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Old 08-11-2010, 02:36 PM   #3
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Mounting the projectors

Get out your projectors, and remove the stock shrouds. They are two screws each on the underside of the projector.

Before you do anything else, tape up the lenses or use cellophane to protect them. You don't want any scratches or hand oils on the lenses or bulbs.



this is when I ran to the local hardware store and got the rest of the things I needed to finish the project:

-8 screws #6-32 x 2 inches
-8 bolts # 6-32
-silscone sealant
-aluminum tape
-electrical tape
-twist connectors (3)
-black spraypaint (I ended up getting gloss)
-silver spraypaint for the shrouds



Grab the projectors, and you will need to remove the bulb, to do this remove the tiny screw on the back of the projector and slide the bulb out



Now unscrew the two black metal rings on the back of the projector, leaving the silicon ring and replace the bulb



Now grab the screws and bolts you just bought, I also grabbed some rubber washers, which I wasn't able to get on every screw becaue the fit was so snug.



take the reflector bowl and remove the part that covers the stock bulb, its just 1 screw on the back of the bowl. Gently slide the projector in, feeding all the wires through the back of the bowl.



This is where the shape of the projector helps us out, it fits perfectly into the factory bowl without having to cut anything.

The projector has 4 holes to slide the screws through. line those up straight with the projector resting in the bowl



mark where the screws line up with the bowl with a sharpie



take out the projector and drill 4 holes where you marked it off



you can now do a mock installation of the projector to see if it lines up fairly straight and make sure everything is solid


Last edited by budahrocket; 08-26-2010 at 12:25 AM.
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Old 08-11-2010, 02:37 PM   #4
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This is where it comes down to some personal preference what you want to do. If you want to keep the projector bowl chrome than you can keep the projector fitted, but I wanted it black with the hella shrouds

I took the projectors out and got everything ready for paint

this is what your table should look like



Be sure to tape up the bezel where the still want it to be chrome, for me this was just the turn signal and parking light areas.

I didn't do much prep work beyond cleaning the bowl and bezel because its sealed up, and I couldn't even get the paint off of the bezel from my koji mod.

I did 3 coats and left them to dry



Clearing the lenses

this is just a matter of how much time you are willing to spend. The longer you clear the lenses the better they will look, its that simple.

If you don't have anything to clear your lenses, I use a foam disc on a corded drill with some meguiars plastic polish.



I spent about 20 minutes on each lens and they turned out amazing.

Wiring

The wiring harness I got with the projectors is just perfect

I did a mock set up of the wiring



There is a power line that goes directly to the battery, plugs for each ballast, a ground for each ballast, high beam solenoid and 4 wires that connect to the factory light plug.

this is how each projector is set up



I carefully picked up everything and moved it out to the garage to hook it up and make sure everything was working.

To hook it up to the car, take the main light plug on the DRIVER side right below the battery and cut it about 1.5 inches back (you will have to remove some factory electrical tape and shrink wrap)

put this plug away



then strip the three wires on the car and strip the four wires on the wiring harness labeled high beam and low beam



connect them as follows:

blue --> red w/ blue stripe
white --> yellow w/ red stripe
both black --> red



hook up the battery power and grounds and turn on the lights


Last edited by budahrocket; 08-26-2010 at 12:28 AM.
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Old 08-11-2010, 02:37 PM   #5
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once you make sure they're working, bring everything back inside

Now you are going to seal up the projectors with the aluminum tape
Make sure you cover all areas multiple times and cover all cracks and seals so no light can leak out.
Also make a note of where the high-beam solenoid is, you want it to be on the bottom, otherwise the high beam and cutoff will be upside down.



when the paint dries on the bowls, and you have sealed up the projectors, you can mount them for the last time



The hella shrouds didn't fit, so I had a lot of grinding to do at this step, but if you use the shrouds the projectors come with they fit without a problem.

make sure to put everything back exactly as it came off, and when you are ready to seal up the lights, lay the headlight housing flat on the table and put a continuous line of sealant into the groove. Re-install the lens, pushing down very firm and wipe away any excess silicon.

hella shrouds:



stock shrouds:



now I did the final installation of the wiring harness





I also left one of the stock lights in to do a comparison. The projector wasn't aimed in the picture, so it was pointed a lot higher than it should of been, so it won't be blinding you anymore, but you can get an idea of how much brighter they are than the stock halogen lamps.



all finished!! I couldn't be happier with how these turned out, and I think I'm going to start on another retrofit pretty soon as soon as I get another set of headlights. It went a lot smoother than I expected and I encourage anyone tempted to just go for it. If anyone would like me to put together this same kit for them just send me a pm (I would give you guys a link to buy them online but there's no website).


Last edited by budahrocket; 08-11-2010 at 08:46 PM.
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Old 08-11-2010, 02:38 PM   #6
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reserved4
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Old 08-11-2010, 02:51 PM   #7
budahrocket
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output/ beam pattern

I'm pretty happy with the pattern, I'll be lowering the cutoff a little from these pictures though. I had to take them apart again for some extra fine tuning because I didn't originally aim the projectors well enough, and this time I put the stock shrouds in. I think they look a lot sharper with the chrome shrouds and I'll be sticking with these in the future. Enjoy!










Last edited by budahrocket; 09-09-2010 at 03:18 AM.
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Old 08-11-2010, 03:21 PM   #8
aleutdude
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Are those the mini morimoto bi xenons?
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Old 08-11-2010, 04:11 PM   #9
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no they're not, haha but I just checked out the mini morimoto's and they look almost identical, should be more or less the same process.
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Old 08-11-2010, 04:21 PM   #10
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2 thumbs up

Good stuff man.
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Old 08-11-2010, 04:30 PM   #11
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Nice work. Very clean retrofit.
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Old 08-12-2010, 04:38 PM   #12
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Any output/beam pattern pics?
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Old 08-16-2010, 04:34 AM   #13
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Quote:
Originally Posted by aleutdude View Post
Any output/beam pattern pics?
As soon as I get the chance to finish aiming them I'll get some pictures of the output, how would I take a picture of the beam pattern? is that the reflection like on a wall?
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Old 08-16-2010, 05:36 AM   #14
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Quote:
Originally Posted by budahrocket View Post
As soon as I get the chance to finish aiming them I'll get some pictures of the output, how would I take a picture of the beam pattern? is that the reflection like on a wall?
yeah, just 20ft or so away from the wall.
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Old 08-19-2010, 01:24 PM   #15
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Looks like a good retrofit
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Old 08-21-2010, 10:52 PM   #16
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what projectors r those and where did u buy them . looks great man and crazy that u didnt have to cut out the light. good walk thru.
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Old 08-24-2010, 04:08 PM   #17
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Quote:
Originally Posted by lilwhiteboy View Post
what projectors r those and where did u buy them . looks great man and crazy that u didnt have to cut out the light. good walk thru.
yaa where can I buy those projectors?
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Old 08-24-2010, 07:18 PM   #18
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Quote:
Originally Posted by lilwhiteboy View Post
what projectors r those and where did u buy them . looks great man and crazy that u didnt have to cut out the light. good walk thru.
Quote:
Originally Posted by japspecjohn View Post
yaa where can I buy those projectors?
thanks man, I still have to do some little adjustments and take some pictures of the output. I'm actually not sure what the projectors are called, I got them from a wholesaler that supplies my business. They're called Vision, but I couldn't find them anywhere on the internet.

If you guys are serious and would like me to get you a set, send me a PM and I could ship them out to you.

Last edited by budahrocket; 08-29-2010 at 03:07 AM.
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Old 08-25-2010, 01:23 PM   #19
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pmed ya
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Old 08-25-2010, 04:33 PM   #20
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im gonna use the mini morimotos...they have kits with plug and play 9007 harnesses for like 275
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Old 08-26-2010, 03:56 PM   #21
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Get a chance to take any output pics yet? Also, you're going to want to solder and heatshrink your connections. Those screw on connectors will allow moisture in and corrosion will be the result. One night you could be driving along and-poof! No lights.
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Old 08-27-2010, 02:49 PM   #22
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Subscribed. Great job OP!
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Old 08-27-2010, 09:53 PM   #23
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Quote:
Originally Posted by aleutdude View Post
Get a chance to take any output pics yet? Also, you're going to want to solder and heatshrink your connections. Those screw on connectors will allow moisture in and corrosion will be the result. One night you could be driving along and-poof! No lights.
Not yet, I'm visiting my sister up north this week, and I'll get some up when I get back. But yeah thanks for pointing that out, I'll heat shrink those connections. Do you think the connections on the ballasts and wiring harness need to be heatshrunk any further?
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Old 08-28-2010, 04:42 AM   #24
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How much did you put in to this money wise? I'm def interested in doing a set!
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Old 08-29-2010, 03:03 AM   #25
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Quote:
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How much did you put in to this money wise? I'm def interested in doing a set!
The kit cost me $200, shrouds were $18 and then I spent about $25 at Home Depot for everything else I needed. So all in all under $250. I will probably be upgrading the ballasts sometime in the future though.

If you want, I can get you the same kit, just add $10 for shipping.
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