Getting around to doing the retro on my 92 pickup. I have had these projectors laying around from my previous retro just waiting to go in the yota.
The projectors are Acura TL bixenon projectors with clear lenses.
The other equipment is Hella ballasts, and a Morimoto H4 relay harness (3yrs old used everyday and not a single issue). Pilot housings which are preferred because of them being completely plastic.





And i got started on one housing already

 

Got both projectors fitted in the housings. I need to install the relay harness so i can test cutoff rotation of the projector.

 

Is there enough room behind the housing to mount these? Are you going to have to cut out the core support or move anything?

 

The core is fine. The headlight bucket on the other hand will need to be cut to allow the projector to protrude through. I do not know how much yet but i dont think it will be that much.
The only thing that i think will need to be addressed is the battery but i wont know that until i set them in place.

 

Getting started installing the harness and test fitting the housings, i ran into a few obstacles.



One housing fit into position



As you see here my battery will now not fit. No way, no how!!



The battery is old and i have another vehicle that needs one so i can sell it, so its going in that vehicle. Now the new battery im going to purchase is made specifically for Toyota....

 

Interested in how this turns out. I'll follow...

 

Got them up and running today. Need to get shrouds fit and test rotation.
Also waiting on new battery to be delivered.

 

Almost finished with the housings. Got a few small touch ups to do and seal them up.

 

Lets see a cut-off pattern shot at night.

 

Working on that. Probably be tomorrow night.
These projectors came out of my other truck so i do have some cutoff pics from them on it.

 

Having a few difficulties. Got one light mounted tonight but need to figure out a way to seal the reflector bowl where the cut off shield sticks out the back of the solenoid. New battery came in but I did not know it had the JIS terminals so I can't install it and with the original battery in place I can't install the other projector and housing.

 

All is left is to seal the solenoid area. Thinking on this one a little.

 

Need to find an adapter for the new battery also. The terminal needs to be cleaned also!

 

just a suggestion..
Why not just epoxy the two housings together?

 

They are JB Weld together just aluminum tape over all the jb weld.

 

Gotcha

the solenoid area is under the projector, with the spring exposed?
Could you use a rigid plastic or ABS then epoxy that to the housing? Maybe a job box from DigiKey or Mouser cut to accommodate the housing.

 

Yea that area. Its open straight to the internals of the projector. I have some old legos my boys dont play with anymore that im going to check out. It wont be much work to seal it since its 4 sided with a top.

 

Sorry kiddos i needed 2 blue legos....



Got them sealed up and mounted. Also got the battery mounted in place, although i still cant put the terminals on the posts.

 

I would just get new battery cables and terminals - pretty cheap fixes from any auto parts store. You'd be amazed at the amount of resistance you can get with old cruddy cables and terminals.

 

Going to test the cables this weekend and clean them then retest. I hope they are still decent so I can just shim them to fit for less than $15 compared to almost $100 for Prius cables.