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Old 03-16-2005, 01:12 PM   #1
Bayley
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Default Xenon Projector Retrofit in a 2004 WRX (6 pics at 1200 x 1600 res)

I leaked a few pictures in this thread,
but I've finally wrapped everything up to a point which I'm happy
with. It wasn't easy and I don't recommend this mod for those with a weak
heart. something about taking a hacksaw to a perfect pair of reflector
housings that made me a little weak in the knees.

Sorry for the dirty car pics, but it's Spring time in Michigan... not much I can
do about it...

Anyway, here's how they turned out:





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Old 03-16-2005, 01:28 PM   #2
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very nice! bi-xenon or single? either way it looks great!
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Old 03-16-2005, 02:01 PM   #3
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Bi-Xenon. The original high beams aren't even hooked up anymore. you couldn't see them over the HID's.
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Old 03-18-2005, 12:20 AM   #4
Hank3
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Looks good
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Old 03-18-2005, 01:32 AM   #5
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nice !!!!

btw just wanta know how much did this project cost u?

thanks
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Old 03-18-2005, 04:48 PM   #6
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Quote:
Originally Posted by coolray
nice !!!!

btw just wanta know how much did this project cost u?

thanks
Nowhere near as much as it should have.

(working for a German lighting company has its perks)
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Old 03-18-2005, 06:03 PM   #7
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i'm curious. I've seen all kinds of retro's on all kinds of cars on hidplanet. but how do you make sure the projector lens is square in the housing so you have proper alignment?
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Old 03-18-2005, 06:47 PM   #8
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Very nice install! Looks great!
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Old 03-18-2005, 07:42 PM   #9
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very nice install
i probabily would of put the bi-xenon where the hi-beam is
cuz the shape of that area is round to match the projector.
but it's nice nothing the less. good job.
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Old 03-18-2005, 09:31 PM   #10
Bayley
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Quote:
Originally Posted by MikeWRX-NJ
i'm curious. I've seen all kinds of retro's on all kinds of cars on hidplanet. but how do you make sure the projector lens is square in the housing so you have proper alignment?
Keeping square with the housing doesn't guarantee proper alignment. My first attempt at the alignment, I measured the projectors to be square with the housings. I drove the car into our lighting lab and my alignment was waaay off (high). Thankfully, I suspended the projectors in the housing with four bolts that use compression springs to keep the bolts taunt. The only limitation to my alignment is when the projector physically hits the trim piece. I have more beam pattern adjustment than I did with the original reflector setup.
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Old 03-18-2005, 09:36 PM   #11
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Quote:
Originally Posted by Kenji815
very nice install
i probabily would of put the bi-xenon where the hi-beam is
cuz the shape of that area is round to match the projector.
but it's nice nothing the less. good job.
I agree with you 100% that it would have looked nicer in the high beam hole. However, there simply wasn't enough room to fit the large(r) projector behind the high beam area. Even in the low beam area, the end of the projector still sticks out about an extra inch and a half than the original setup. I had to make some rather creative caps to seal up the housings in back.
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Old 03-19-2005, 06:49 PM   #12
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Quick question.. slightly OT. What's the difference between bi-xenons and single?
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Old 03-19-2005, 07:09 PM   #13
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Quote:
Originally Posted by InfamousDX
Quick question.. slightly OT. What's the difference between bi-xenons and single?

bi xenons are low beam high beam both xenons


singles are not


btw, those are really nice. Any pictures of them at night?
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Old 03-20-2005, 11:03 AM   #14
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Quote:
Originally Posted by InfamousDX
Quick question.. slightly OT. What's the difference between bi-xenons and single?
In all projectors (be it a Xenon or Halogen bulb) there is something called a "DOT shield" that essentially blocks the upper portion of the beam pattern reflecting from the projector. This shield provides maximum lighting to the road surface while keeping glare to on coming drivers to a minimum. Projector lighting setups are known for creating less on coming glare than the standard reflector style housing.

On “Bi-Xenon” projectors, there is a V shaped notch in the DOT shield that exposes the center-focused portion of the beam to the projector. Under normal (low beam) operation, there is a “semaphore” (flat piece of thin metal) that blocks the V shaped cut out in the shield. When the high beam switch is activated, a solenoid pulls the semaphore down exposing the V cutout.

So in actuality, all the Bi-Xenon does is expose more of the shielded beam pattern in high beam mode. The bulb light output itself is exactly the same between high and low beams. It’s a pretty intriguing concept, a single high beam that consumes less energy than a standard Halogen Low beam. Lets also not forget, the WRX / STi continues to use the low beams when the high beams are actuated… even more power consumption. Not that power consumption is really in issue with these cars, but it’s a neat concept.
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Old 03-20-2005, 11:34 AM   #15
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not to mention the INSANE amount of light thrown off by them in high-beam mode. My g/f's father has an acura TL and I litterly got gitty when he let me drive it and i turned on the high beams.

any plans on posting beam pattern pics?
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Old 03-20-2005, 12:40 PM   #16
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i think the lights look great and would like to know more about the whole process!

did you wire the ballasts into the existing relays so you can use the OEM lightstalk to control it?

do you have any further plans for the hi-beam 9005 locations, since they're not adding any lighting to the hi-beam xenon?

can you get a few night pictures from behind the car looking out over what it lights up?


and lastly, awesome mod!

Last edited by Mulder; 03-21-2005 at 04:11 PM.
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Old 03-20-2005, 08:52 PM   #17
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You guys are lucky I’ve already seen the Godfather a few millions times (playing uncut
on Spike TV as we speak)…

Here are a few beam pictures I just took:

Low beams about 20 feet from garage. I intentionally kept the drive beam just a touch
lower than the passenger. Notice the crisper cutoff on the passenger side beam. I tried a
few “tricks” to the semaphore, which appeared to have worked.


Now for the high beams:


Unfortunately, my camera didn’t realize I wanted a picture of the world outside my car and not my gauges… oh well. Low Beams:


High Beams:


OH NOES!!!1!!1!!ELEVEN!! Its teh Mad blind y0! (low beams):


Now for the real blinders (notice the lack of fog lights):
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Old 03-20-2005, 09:06 PM   #18
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Quote:
Originally Posted by Handsdown
did you wire the ballasts into the existing relays so you can use the OEM lightstalk to control it?
Yup. Everything behaves the exact same way any normal car would. I did, however, have to add a couple relays to power the ballasts. Under normal operation, the HID Ballasts only consume roughly 10 amps each. However, the startup current consumption is over 50 amps. I'm running a direct feed off the battery to the relay with a 60A in line fuse for each ballast. The wires that went to the original headlamp are now powering the coil on the relay. The best part about this, I didn't even need to cut the original wires. The factory connectors for the low beam fit perfectly on your run of the mill 12V automotive relay.

For the bi-Xenon solenoid, I simply ran the coil wires directly into the original plug and masked them off with electrical tape. I realize this is sort of crude, but I wanted to keep as much of the wiring untouched in case I ever decide to go back to the original lighting setup. Besides, the bi-Xenon solenoids pulls about 0.3 amps... a far cry from the 50 amps available. I think I'm safe.

Quote:
do you have any further plans for the hi-beam 9005 locations, since they're not adding any lighting to the hi-beam xenon?
I'm undecided right now. Both of the high beam reflectors sustained some sort of damage during all my trial fittings and construction methods. The only reason I left them in there was purely for cosmetic reasons. I supposed I could start looking at some other options and get rid of the OEM reflector housing completely.

Ya know, I do have a second set of ballasts and xenon bulbs floating around...
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Old 03-21-2005, 03:42 PM   #19
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So how much would this cost in the "real" world for us non privileged types who don't work for German lighting companies?

Excellent, BTW!!!!
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Old 03-21-2005, 03:42 PM   #20
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HOLY CRAP!!!

52xxx miles. Damn!!! You must live in your car.
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Old 03-21-2005, 03:56 PM   #21
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what does the rear of the housing look like?
how did you make the item to aim correctly?
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Old 03-21-2005, 04:14 PM   #22
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Cleaned up this thread, all flames gone.
On-topic discussion only, thank you for your cooperation.
- The Mgmt.
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Old 03-21-2005, 04:15 PM   #23
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Quote:
Originally Posted by Mulder
Cleaned up this thread, all flames gone.
On-topic discussion only, thank you for your cooperation.
- The Mgmt.
You took all the fun out.
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Old 03-21-2005, 04:18 PM   #24
Bayley
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Quote:
Originally Posted by subieworx
So how much would this cost in the "real" world for us non privileged types who don't work for German lighting companies?
I'm not 100% sure, but I believe you should be able to pick up the parts on E-bay for about $400 - $500 (projectors, ballasts and bulbs).

As for the the aiming, I have the projectors held in place by four 6-32 bolts that are spring loaded between the projector and plastic housing. To aim the beam, I simply tighten or loosen the nut on the bolt that sticks out from the rear of the housing. It's a pain in the butt since I need to pull the assembly out of the car to align the beams, but not really that big of a deal. Especially since its something that really only needs to be done once.
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Old 03-21-2005, 04:19 PM   #25
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Quote:
Originally Posted by Mulder
Cleaned up this thread, all flames gone.
On-topic discussion only, thank you for your cooperation.
- The Mgmt.
Thank You
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