Okay, so the subject line might be a bit misleading...



Other larger images here:
http://www.haveblueonline.com/headlights/P8150010.JPG
http://www.haveblueonline.com/headlights/P8150004.JPG
http://www.haveblueonline.com/headlights/P8150006.JPG

Pictures of completed project (sans rodentia) to follow.

 

Is that a hamster?

 

That would be "Skippy" the hamster. He's friends with "Jiffy" the mouse (my wife's).

 

Looks clean, can you tell us what you used and do an overview of the process you did, w/ pics?

Any shots of them on teh car and on?

 

Finishing the passenger side as I type this. Should be all wired and ready to go by tomorrow morning.

I haven't taken many pictures to create a -step-by-step. However, I can tell you that it involves cutting out the back of the stock headlight with a Dremel tool, using another rotary tool to widen that hole and smooth it out, painting, epoxying, creating A LOT of dust and an equal amount of frowns from my wife, repeated trips to the parts store for miscellaneous fastners, and a lot of thought and rough sketches.

I started this project on Saturday. Originally I was going to use two pieces of sheet metal cut and shaped to resemble the glass on the headlights. I actually formed a really nice looking metal "lense". But upon dry-fitting it, I decided it would be way too much work and probably wouldn't look right anyway. I was going to use the metal as a frame to mount high- and low-beams side by side. The problem was space, appearance, and mounting. I was basically reinventing the wheel at that point. So, instead of doing away with the whole headlight unit, I thought about removing the lamp and using the bracket. Then I realized that wouldn't have worked due to space constraints. Then I thought about removing the chrome reflector and using just the glass. Once again, space was an issue. So, I decided to cut the back of the reflector out and push the projector through the hole and securing it with epoxy. Space is still an issue as the back of the projector extends about 3" beyond where the H4 bulb does. That leaves about 1.25" between the H9 bulb on the projector and the battery on the driver's side. The result is that the stock lamp is now low-beam only. I have yet to determine where I want to place the high-beam 90mm lamps. Popping a couple holes in the bumper is looking more and more appealing. That would make my TJM bumper look very similar to the ARB bumper.

I will have more pictures tomorrow. At that time, I will probably delete this thread and create a more appropriately named "projector headlight conversion" thread. I'll probably include a poll to see what kind of interest this generates. If there's a lot of interest in a write-up, then I'll create one.

 

I'd definitely be interested in a thorough write up

 

Me too!

 

oh teh good ole hella 90mm projector. they work well and im selling a pair as well.

 

i thought u went hids, poooo! = (