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Old 03-12-2012, 08:11 PM   #1
mattesonb
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Default my 2011 wrx TRS retrofit did not go well... need some input from those that have it

so my 2011 wrx trs retro quick didn't go so well. mainly i am having 3 issues;

1. the ds2 lens seems about a half inch too deep into the housing, this is leaving a noticeable gap that makes it so you can see the housing screws. the housings also dont line up with the hole making it look strange from in front of the light

2. i'm getting a rogue light leak above the cut off on both headlights, it looks like light is being allowed to escape because the ds2 is too far back

3. having a lot of difficulty getting them aligned as passenger side isnt sitting level with the driver.

here are some photos

light leak


headlight gap and misalignment

passenger


driver
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Old 03-12-2012, 09:00 PM   #2
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the gap between the projector and housing is normal.

The misalignment maybe off due to reassembling the housing.

Also check to see where the rouge lighting is coming from. If you can find it see what is causing it. (Ex. misaligned housing, crack caused by disassembly, etc.)
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Old 03-13-2012, 07:27 PM   #3
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some more photos


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Old 03-13-2012, 07:37 PM   #4
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Sux hearing about all these problems with this kit. Im really nervous to install mine now.
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Old 03-13-2012, 11:02 PM   #5
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Those 2 spots above above the cutoff are light coming from the partially blocked squirrel finders. The cutoff shield has bent in tabs to hold the pivoting cutoff shield. A blockoff plate is on the backside meant to cover the holes. The block off plate needs to be adjusted.
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Old 03-14-2012, 02:22 PM   #6
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Quote:
Originally Posted by apkarian100 View Post
Those 2 spots above above the cutoff are light coming from the partially blocked squirrel finders. The cutoff shield has bent in tabs to hold the pivoting cutoff shield. A blockoff plate is on the backside meant to cover the holes. The block off plate needs to be adjusted.

this is a bi-xenon trs retofit kit, there is no squirrel finder any more. but thats not the issue, others have done the same kit in the same headlight without it
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Old 03-14-2012, 03:46 PM   #7
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I understand this is the bixenon kit, but the fact still remains, the bent tabs on the cutoff plate that hold the pivoting cutoff shield let light escape from the bowl. Morimoto puts a blockoff plate on the back side of the plate on the Morimoto D2S projector to cover up the holes. In my experience retrofitting several headlights, the blockoff plate doesn't completely block the holes and needs to be adjusted. These are mass produced projectors without perfect QA standards. Many of these projectors still need final adjustment.
Quote:
Originally Posted by mattesonb View Post
this is a bi-xenon trs retofit kit, there is no squirrel finder any more. but thats not the issue, others have done the same kit in the same headlight without it
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Old 03-14-2012, 04:20 PM   #8
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Just went out and took a look at mine, they have the same "gap" however no bright spots. I was able to level them, and have not had any issue since.

So I think the gap is normal on these, not sure about those hot spots though...
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Old 03-14-2012, 06:10 PM   #9
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Quote:
Originally Posted by dsmtweaker View Post
Just went out and took a look at mine, they have the same "gap" however no bright spots. I was able to level them, and have not had any issue since.

So I think the gap is normal on these, not sure about those hot spots though...
i'm hoping that because mine still need a good amount of adjusting that it is simply a result of the alignment being off and nothing more.

i am re-baking them this weekend to re-clean the lense so i am going to double check where exactly that reflection is coming from one the housing is open
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Old 03-15-2012, 12:50 AM   #10
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How do you fix rotational alignment? I did 2 retrofits, first was a mini d2s then OEM sti HID projectors. Both have been off rotationally (not by much). There is 4 screws that hold the projector in place, not much to go wrong (or so I thought). Can I adjust rotation of the whole assembly by putting spacers on one side?
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Old 03-15-2012, 01:11 AM   #11
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Quote:
Originally Posted by mattesonb View Post
this is a bi-xenon trs retofit kit, there is no squirrel finder any more. but thats not the issue, others have done the same kit in the same headlight without it
There's really no other explanation for what you see in the pics though. It's definitely the holes in the cutoff shields. If it isn't then I'll honestly be surprised. I can't think of anywhere it would reflect off of and look like that.

Quote:
Originally Posted by mattesonb View Post
i'm hoping that because mine still need a good amount of adjusting that it is simply a result of the alignment being off and nothing more.

i am re-baking them this weekend to re-clean the lense so i am going to double check where exactly that reflection is coming from one the housing is open
The way the light is coming out (color and shape) doesn't look like a reflection.

Last edited by Andrew025; 03-15-2012 at 01:45 AM.
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Old 03-15-2012, 01:34 PM   #12
apkarian100
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Only way I can think of adjusting rotation is making the holes wider on the retro-quik brackets so you can move and aim the projector while in the housing.
Quote:
Originally Posted by doomskies View Post
How do you fix rotational alignment? I did 2 retrofits, first was a mini d2s then OEM sti HID projectors. Both have been off rotationally (not by much). There is 4 screws that hold the projector in place, not much to go wrong (or so I thought). Can I adjust rotation of the whole assembly by putting spacers on one side?
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Old 03-15-2012, 03:26 PM   #13
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Quote:
Originally Posted by Andrew025 View Post
There's really no other explanation for what you see in the pics though. It's definitely the holes in the cutoff shields. If it isn't then I'll honestly be surprised. I can't think of anywhere it would reflect off of and look like that.



The way the light is coming out (color and shape) doesn't look like a reflection.
you may be correct, though i dont know how i would fix that a there is no longer a squirrel finder. there is simply that spring loaded plate that moves out of the way when the high beams are engaged.
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Old 03-15-2012, 07:15 PM   #14
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It's really not a squirrel finder. I worded it wrong. Sorry. You have to open the light, take out the projector, unbolt the lens holder from the bowl, unbolt the cutoff shield from the bowl and you see two screws holding the solenoid to the shield. The screws also hold the blockoff plate. Adjust that plate so it covers up the holes. Done.
Quote:
Originally Posted by mattesonb View Post
you may be correct, though i dont know how i would fix that a there is no longer a squirrel finder. there is simply that spring loaded plate that moves out of the way when the high beams are engaged.
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Old 03-15-2012, 07:32 PM   #15
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Very odd indeed. Fwiw, I don't have an issue with the Mini D2S I'm using. For the benefit of this discussion, here's how the plate & solenoid assembly looks on mine. I don't have a picture of the backside. Either way, there doesn't seem to be any opportunity for light to escape from the bottom part based on this picture.

To the OP (mattesonb), how far up does the high beam pattern go? Does it go up to those "leaks"? Could the bottom of the high beam plate be slightly bent, or the hinge be positioned a little too high, allowing light to escape through past the bottom of the solenoid spring?
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Old 03-15-2012, 07:54 PM   #16
apkarian100
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In this pic, the 2 spots I circled, is where light has a chance to escape. On the back side of the cutoff plate is where the block off plate is mounted. You can't see it from this pic. I've seen a couple sets of projectors now where the block off plate doesn't fully cover the holes. The pic below looks to be fine and fully covered.

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Old 03-15-2012, 07:58 PM   #17
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hmm, i plan on disassembling them tomorrow and taking a closer look. i'll post photos as i go.

the light does seem to be coming from 1 center point so that may be the culprit
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Old 03-15-2012, 11:29 PM   #18
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Rotational aligment is a PITA on those, I gave up. I'm really surprised though that your hotspots are below the cutoff - during my first install, they were significantly above it. I had to modify the position of the D2S bulbs by putting little wires in between the bulb plate and the protrusion that holds it in the housing, and even that wasn't enough. Your output looks great, IMHO even if it won't line-up. Curious to see if your halogen high beams remained aligned though (which can be seen easily if you have DRLs)
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Old 03-16-2012, 07:02 PM   #19
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here is a photo of my housing

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Old 03-16-2012, 08:30 PM   #20
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Quote:
Originally Posted by mattesonb View Post
here is a photo of my housing
Hope you don't mind me editing the image...

At the bottom of the solenoid coil (on the leftmost edge in your picture, just before the solenoid box, roughly outlined with an orange box), is that an opening that is covered by another plate with the same color as the high beam plate? If that area has a slight hole, it could certainly generate a bright spot in the right area you shown in the initial wall pattern.
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Old 03-16-2012, 08:35 PM   #21
mattesonb
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Quote:
Originally Posted by satrya View Post
Hope you don't mind me editing the image...

At the bottom of the solenoid coil (on the leftmost edge in your picture, just before the solenoid box, roughly outlined with an orange box), is that an opening that is covered by another plate with the same color as the high beam plate? If that area has a slight hole, it could certainly generate a bright spot in the right area you shown in the initial wall pattern.
i see what you pointing at, i double checked it when the ds2 was disassembled and its definitely blocked
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Old 03-19-2012, 02:37 PM   #22
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I am not being told that this is simply a common side effect of the d2s projector and to simply ignore it. i am pretty pissed that i'm expected to just ignore a blinding rainbow effect coming out of my retrofitted housing...
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Old 03-19-2012, 02:43 PM   #23
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I guess you didn't resolve this issue yet after taking them apart again. Has TRS given you any ideas what this could be? I'm gonna hold off my install cause I definitely don't wanna go through this!
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Old 03-19-2012, 03:41 PM   #24
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Quote:
Originally Posted by slimfit View Post
I guess you didn't resolve this issue yet after taking them apart again. Has TRS given you any ideas what this could be? I'm gonna hold off my install cause I definitely don't wanna go through this!
TRS is telling me it is a common issue with the D2S and the cut off shield... i think its a bunch of bull****
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Old 03-19-2012, 03:48 PM   #25
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Too bad you've already re sealed the headlight housing. The fact remains that:
(1) There doesn't seem to be anything visually different from other Mini D2S units (or more precisely, other D2S owners haven't spotted any possible cause).
(2) The effect appears equally on both headlights.
If it was a one off "defect", then having it happen on both seem unlikely. If it was a "design change" relative to previous D2S, then it might be visible from the pictures.
What about the shrouds? Could the inner side of the shroud, combined with the depth of the shroud relative to the projectors, cause some light that should've been bent down by the projector lens to deflect somehow? I'm not talking about the outer surface of the shroud, which you've painted a flat & dark color.

I find it surprising that TRS believed this to be a common D2S "feature". If it's also on mine, I don't see it. (here's how it looks before adjusting the hotspot & rotation alignment on the left one)
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