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#1 2014-05-20 04:25:19

Bradrcr
Beer Jedi
From: Renton, Wa
Registered: 2012-05-16
User Number: 7247
Posts: 569

How to install HID Projectors + almost every other headlight mod

First off, I suggest reading this ENTIRE thread before starting ordering your HID kit. I've tried to include all optional steps so nobody finds themselves wanting to open their lights back up once finished. In particular, read through how the shrouds are mounted, since certain shrouds may not fit at all. If you do all the steps, it may be possible to do it in a day, but there's some drying time with some of the steps (it can be baking accelerated), so I'd make sure you have 1 1/2-2 days available.

Tools and parts:
Drill/driver
Bits:
8mm
10mm
Philips head Screwdriver/bit
Flat head screwdriver
Dremel with cutter wheels, a large grinding stone, and diamond point
80-120 grit large drill Sanding drums
Rubberized twist ties
Male/Female butt connectors- red (read through for specific styles)
Shrink tubing and heat gun
Rubbing alcohol
Tin snips
Painters tape

Recommended::
Solder and soldering iron
Small pry bar with flat side
Rubber caps
Electrical tape
Industrial strength velcro

Optional for lens clearing:
800-1000 grit pad
2000 grit wet/dry sandpaper
Rubbing compound

Optional for LEDs and Halos:
Push pin
Thinnest gauge hangar wire (.58mm)
Smallest drill bit possible

Optional for clear reflector:
Fluorescent light insert (Info in instructions)
Amber replacement sidemarker bulb
Clear heat-tolerant adhesive

For ordering, there's really no better source than theretrofitsource.com.  To note, there will be some small color differences, and possibly one or 2 minor wiring differences you will see in my equipment in this how-to. I did order my projectors and wiring from Autoretrofit. You can find them on various online sites, they do appear to be identical to Morimoto Mini projectors (I was not able to confirm if they were the same/rebranded items), and I only decided to take the chance on these after reading many positive reviews. However, the Morimotos and any other retrofitsource items are your closest guarantee for top notch, and if any of my parts fail down the line, I will be getting my replacements from them.

If you're ordering the same items as in this How-to, your order will look like this:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/Lighting%20and%20Electrical/Screenshot2014-04-19120333_zps4c942412.png

http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/Lighting%20and%20Electrical/Screenshot2014-04-19120315_zps918159d5.png

The one item not showing that I also ordered are 100mm Halos, and I did get an extra pair of shrouds, which is not a bad idea with the overstock deals on theretrofitsource.com to have a little insurance. You'll need to refer to the specifics for your shrouds to determine what halos to buy, and keep in mind that the LEDs and Halos run at 5000k if you're looking for a good projector bulb color match.

I recommend testing all parts before you start working, it would suck to get partway through and realize that one of these is dead. I use a jumper box with a set of clip wires attached:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/699C974E-BFDF-4FF4-B690-8646B937528C_zpsfogzcyl4.jpg

Next, line up your original headlights and tape off their pattern against a wall or garage door. I did this in a pretty minimal manner so as to not tick off the wife, and in the end it peeling off because of heavy rain, so try to do it inside the garage if you can if you live in Seattle like me:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/A1350040-8945-4715-9C3F-07FCEB417A47_zpsubnatyz8.jpg

Also take some before pics as a reminder:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/81700E07-A80B-4630-BC5C-6815429CACDB_zpsyflmlnxh.jpg

Now you're set- remove your bumper cover. If you don't already know how, here is my how-to: https://saab92x.com/viewtopic.php?id=41352

Now you're ready to remove your actual headlights, here are instructions for that: https://saab92x.com/viewtopic.php?pid=685423

Next, remove the bar from the bottom of the headlights that the bumper cover clips to; it's just one screw on each side. Follow this by removing the 2 small black screws from each end of the headlight that attach the black housing to the lens.

Take off the cap covering the back of the low beam:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/ADB4B0FD-CE2F-4C90-9FCA-6E5D15FCCF2C_zpsmefsis8e.jpg

And remove all your bulbs:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/FAF14004-8902-48A8-AF8B-72A6A16E2518_zpsvzuc5zoc.jpg

Now it's time to bake your lights. I STRONGLY suggest baking for 20 minutes at 200 degrees. I took the advice from theretrofitsource and did 270 for 7 minutes. This wouldn't be the end of the world, but I really screwed up and forgot that I had lowered the bottom grate for baking something else and near the end of this thread you'll see the results sad ALWAYS bake on the middle oven shelf or higher.

Now it's obviously time to separate your headlights. This is fairly self explanatory; you'll need a flat head screwdriver to lift some of the retaining clips, and I recommend a thin small lever, it's best to insert it into the seam then twist sideways.

Now remove these screws that connect the reflector to the lens:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/28AEE69E-76B1-48C0-81CC-F0B125C4E45C_zpsklxrcfya.jpg

Optional Step- Lens Clearing:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/6B63BFBB-028B-4DF2-A615-D23B83110866_zpstxwcfquk.jpg

My lenses were as yellow as they get, and the UV layer on the inside was burning off and needed to be completely removed. Here is the method I used:
First I hit the inside with the 800-1000 grit pad until the UV layer was gone, followed by 2000 grit wet sanding, then 3M rubbing compound. Here is one of my lenses before removal:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/92C76E7C-8D95-4456-A802-0C13A2B06F4E_zpsmz2e4gdp.jpg

Here is my untreated lens on the left next to the right one I had done the inside of:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/0D2EEAFF-6C65-4609-9AEA-2B163936D0E0_zpsazogf0oz.jpg

For the outside I went through the whole process with the Headlight Lens Restorer package. The difference is at the end you want to use the lens base coat wipe followed by the lens sealing wipe on both the inside and outside of the lens. The lenses had a bit of texture, but were FAR clearer; here are the finished lenses:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/E28A651B-EA17-4E43-8AE7-423760A4B7D2_zpsiw75itwo.jpg
End Optional Step

Pull out this grommet and all the attached wiring though this hole:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/CFE7E6BF-3D64-410F-98EB-255F649A565A_zpsm7d8gxlu.jpg

Remove the rubber cap from the horizontal adjustment screw and reverse it as far as it will go. Then tighten up  the vertical adjustment screw until you can see these screws securing the top of the reflector, then remove them:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/138F9572-C027-4DE9-BE32-DBCF0EEAEAF5_zpsgvagugfu.jpg

You can now fully loosen the horizontal adjustment screw, pull the reflector free and remove these adjustment nuts so they won't fall out at a random time:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/27452B3F-7DBC-4676-9A99-180D8A3A2108_zpsfw5xghhy.jpg

Unscrew and remove the stock low beam bulb mount and forward reflector and then draw an oval line like this:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/E87B1AE4-56F5-4FDB-8D91-E00FD64E7306_zps3zc7jnzv.jpg

Now use the dremel and cut out the line. You can use a cutting wheel to cut off the posts and the very top and bottom, but a diamond tip is best for the curved parts. Careful not to cut too wide, otherwise the projector will sit  too deep in the reflector and you'll run into your cap:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/E73AB82D-5691-4FC9-85C4-B1A92115D5F8_zpsnh2d9fmv.jpg

Next grind down most of the parking light mount, in particular near the top where it's closest to the hole you just cut. Just be careful not to cut too deep, you'll want some plastic between the 2 holes to help with stability:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/958ED04C-AEB5-4E4A-851E-EF741934F925_zpsbykttdcr.jpg

Finally, sand out the edges of the oval  with a 120 grit drill drum sander, or if you're very skilled, a grinding stone on the dremel.

Trim out the center of the large silicone washer, tin snips are the easiest, should look like this:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/7E034BB1-2536-4AE3-8116-FBBDB80D64CA_zpsr42hm0d9.jpg

Twist tie the wiring on the projector; it's not needed since we're using the stock brights:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/262F7975-E352-4850-BC68-3EF9DD918A91_zpsyit4zfr4.jpg

Secure the projector to the reflector as shown, trim down the parking light mount if still needed, and maybe sand the opening more. You should have a gap on the sides of the bulb mount.
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/0BD62510-02FC-4292-80AC-7EE2CCDA338B_zpsboofnt1n.jpg

Do a temporary reassemble to check clearance with the lens. Don't press the lens and reflector together, just spot check that if you pressed it all the way in that it at least appears reasonable that the projector wouldn’t hit.
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/AD140A24-CBCC-4AF6-AB7D-DA065FC087B3_zpsrdsyda86.jpg

Once you're somewhat confident that the projector lense will clear (And if you've done everything like in the pics it should), try putting the opening of one of your shrouds over the projector backwards like this:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/C1CE8A62-DEBC-4A3D-9C63-B9D0F78641F8_zps79md5udt.jpg

If you purchased a shroud with a 70mm opening (All these dimensions are listed on theretrofitsource.com web site), the shroud should be able to slide on tightly up to about 1/2 inch onto the projector. If the shroud doesn't go on at all, or only a very small amount, we'll need to sand it to a larger diameter. Us your largest 80 grit large drill drum and slowly rotate it around the inside of the opening of the shroud while running the drill. Test it back over the projector every few rotations until you can slide it on but have it still be snug. Make sure that you also rotate the shroud around in your hand holding it every few passes to make sure you aren't ovalling the opening.
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/D171D973-CE87-421F-B82A-282FF1D6F2A2_zpsbr4iqf1m.jpg

Note: for the projectors to be adjustable to perfectly horizontal, you will need to have 1/4-1/2" more plastic on the bottom half of the shroud than the top, check this lineup throughout the cutting/sanding process.

Line up your shroud with the reflector and projector to see how tall it is versus them. If it is taller (it most likely will be), cut the top and bottom to be flat and in a manner that leaves the shroud still about  1/4" taller than the reflector housing. If your shroud is already flat on the top and bottom, then cut out the flat sections with the dremel. Keep in mind that our lights are angled, and you will want any shape on the shroud to be lined up with the horizontal indent on the back of the reflector, and not the top and bottom edges of the reflector itself, which you will need to cut on an angle to match with. Either way, your shroud should look like this pic, and save these large pieces that you cut out:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/961F9DDE-ED18-4155-B610-18E0F24304FF_zps9qwp53zs.jpg

Belt sand the flat sides of the shroud until you can slide the shroud on as far as it can go and really see how it is lining up with the horizontal guide section.
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/7F4DA068-F939-4E60-AFF9-A4F3C400AE6A_zps9xn7xmk1.jpg
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/8CB36CEA-ED68-4BBA-996C-7D2CEFF71BEF_zpsnb68a6ah.jpg

I suggest cutting down the sides of your shroud 1/4 inch at a time, or even in thin 1/4 inch thin  triangular strips, using a dremel cutting wheel, and then sand the edge with the belt sander once it's close to being a fit:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/D076F79D-B175-4EC0-96ED-ED199E7E637C_zpsyyst6nrg.jpg

As you're going through the process, continue to keep an eye on the lining up with the horizontal lines on the reflector. If you take it gradually, the shroud should slide on well over the projector and be tightly held:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/604A6B9C-1554-4D7F-B44B-5010BE1F8B0B_zpspc6xammy.jpg

Optional Step- Install Halos:
I took the suggestion from theretrofitsource.com to use hangar wire to hold my halos in place. Use a pushpin to 'mark' your drill spot for the hangar wire to hold your halo in place. For best hiding, I used a spot in the outside lower part of the shroud and the inside upper part of the shroud.
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/0F8998F4-C7D4-45E8-A3CB-BAEB1272E14B_zps0uhvqsrz.jpg

I then used my smallest bit and drilled out these holes (Those aren't scratches, just really weird reflections).
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/31CA5FBD-D56B-4B4C-A73F-CA46462D05B8_zpsdpryxvpj.jpg

Cut off two 3" pieces of hangar wire and push it through the hole, then loop it around the halo and twist it behind (use pliers as needed) to hold in place. Keep in mind that you'll be undoing this if you plan to paint your halos you'll be undoing this step later.
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/B409F99C-9E30-44CA-88C6-1AF52706D4F5_zpspd2tawcs.jpg

Run the halo wiring through the parking light hole, reinstall the shrouds and then test for light 'leakage'. If there's a little out the top, don't worry, it will be covered by the lens chrome. If it's elsewhere, you can use the plastic you saved earlier from chrome cutting and some jb weld to block it off:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/AAC4D1F5-CC87-4E7D-9685-97315071D560_zpsfnapzybt.jpg
End optional step.

Now repeat these steps for the other headlight before continuing

Optional step, LEDs:
If you have purchased LED strips, first test fit them to make sure they fit if you're putting them in a tight spot, such as in my case, where I have them sandwiched between the lens and its chrome insert. If you want to get theretrofisource.com LED strips THEY WILL NOT BEND MORE THAN A LITTLE, so plan on buying a couple of strips if you're trying to turn your car into an A4. Once you've confirmed that they'll fit, use the 'pin and drill method as discussed in the halo section for 2-3 holes (or pairs of holes) to hold your LED strip in place:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/F3394143-BCE9-4A21-A989-EA6616E30A67_zpsvynrgqtb.jpg

To make them blend in easier, I recommend using black shrink tubing to cover the white end of the LED strips, then a smaller shrink tubing for covering its wiring. You will need to use a small point or screwdriver to pop out the pins and remove the plastic fitting at the end, but reinstall the fitting once finished.
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/6E51933A-131C-4392-9903-73E384B772FE_zpslijmzd1k.jpg

If you're not planning to Koji Mod (paint) your headlights, go ahead and wire your LED strips in, and use your adhesive backing for some security and preventing them from shifting if they're on an edge like mine. otherwise, move on to the next optional step.

Optional step- Koji Mod:
Here is the pattern of taping off I used to Koji mod. I essentially blocked off just the side reflector area and the reflector bowls for the blinker and the brights. Despite painting the vast majority of the chrome, the shrouds add quite a bit and if you want a very black headlight, it's worth considering painting the shrouds as well:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/4C366FCF-FEE0-4549-A46A-0026852804D8_zpslimiynpb.jpg

Spray the chrome with Krylon hi-temp flat black; it is not necessary to sand first. I recommend then baking in the oven for 45 minutes at 160 degrees to avoid melting plastic:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/8AEEBBA5-0B92-492D-8A9D-FE4C8953059E_zpsg8oqspyb.jpg

Here's the final result:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/46018222-4708-419A-8D13-175E334A8305_zpsgnlis9cu.jpg

Now install your LED strips, and if you painted your shrouds, your halos.
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/77780C67-8EDE-4F64-A02B-3E97F2216DA4_zps0ryfltk4.jpg

Optional Step- clear reflector:
Since they do not make a clear reflector for our cars and the custom molded ones are especially daunting to make, I've found an alternate method. I went to my local plastics store (Tap Plastics) and picked up an insert for a fluorescent light. The one I bought was about $15 and I picked it up since I assumed our reflector would have to bend. I suggest buying the sheet for about $30 with points closer together, it will be more similar to an auto reflector.
First, cut out a 6" x 6" square from your plastic sheet using a dremel cutting wheel. Next line up your stock amber reflector , put painters tape down in a shape that would go around the edges of the reflector and then outline it with a marker.
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/BB6EC6BC-EE90-4058-BB6C-BB2030865DDC_zps0ajrsv4a.jpg

Next, cut out the clear reflector with whatever dremel tip you wish. Then pick away any burnt plastic, remove the tape, and then grind down the edges of the clear reflector with the drill grinding drum:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/65570BDC-BA70-4A3F-A4AA-F8A16F4912D8_zpse7fhrruv.jpg

To install the reflector, I recommend putting some clear adhesive on the center of the top and bottom and tape it in place there to the headlight frame. It is probably easiest to flip it up reflector side down and prop it against something to stop the adhesive from leaking out.
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/27ABEF28-8D73-4605-BD6B-D8DC5BD922E2_zpsullpc8v0.jpg
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/21B91050-BA0D-4C73-AA4B-3E13E047DDE0_zpsrj3cqops.jpg

End Optional Steps

Next lay out your full wiring harness. This will vary slightly in appearance depending on the options you select, but here is what most of you will wind up if you preassemble everything to get an idea of how it fits together:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/6D494F9C-83B5-4FEF-B783-1DD9880C253A_zpskadikppu.jpg

I've already started to take couple of steps since I (and most, I assume) will be retaining to stock high beams. First off, remove the wiring for the optional bright connector from the grommet as shown on the right:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/CFE04118-ED3D-4943-8BFC-C0A33D1B6AD6_zpsq65rwesl.jpg

Next, we'll want to cap off the bright trigger wire on the 3 prong harness. For me this was a blue wire (and you can wire up your projectors and trigger them with the testing rig), and was accomplished simply by covering it with a piece of electrical tape and a small sleeve of shrink tubing:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/2780A128-EEA6-44C0-9CA6-E39F0E281DA8_zpsloa8mj1p.jpg

Finally, put rubber caps over the trigger wires for the projector high-beam cutoff:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/E3C9BA6A-25EB-4F97-9F24-7B229E158092_zpsidi8ufzm.jpg

Optional step- Quick connect for projector bulbs:
During assembly, I realized that if you have a bulb burn out, you will need to completely DISASSEMBLE YOUR HEADLIGHT. Well, that's a pretty lousy prospect, so I put quick connect posts in line for my H1 bulb wiring between the grommet and the bulb. This way, if I have a burnout down the line, I will have to put the same connectors on my new bulb and then I'll be good to go via the standard dust cover. This also makes assembly of the light easier without the bulbs flopping around. You can you the smaller red connectors here; I just used my blues since they had a sealing shrink tube attached.
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/77A82FDE-5B31-4BF5-99EF-4A69E5D7635C_zpsbqidhlsm.jpg

End optional step.

Now it's time to wire up your lights. Start by cutting off the female connectors from your driver's side headlight that originally connected to your stock low beam bulb and its grounded base. Pull the 4 wire grommet out of your headlight and then pull the wires out of the grommet entirely.  Strip the ends of the wire and then replace the old connectors with shielded female connectors and test fit them on the 3 prong connector. If yours is anything like mine, the prongs will be large and you'll have to stretch out your female connectors a little:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/72EB1CCA-B2D4-4F15-9E78-3D495BF6F0E4_zpsrpjzdedt.jpg

Since those prongs are also a bit long, you'll now want to add a little shrink tubing to your female connectors to help weatherproof the connection by 'extending' them:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/B9FEAC4B-8401-4822-948D-3D71C24491B6_zpsvb0bwx0t.jpg

Cut the two wires off of the parking light bulb housing, remove them from the stock grommet, then push them through the holes in the new grommet and then through the stock grommet hole along with the connectors for your new H1 bulb:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/CF5EBBF7-FD71-449C-AA08-21734C58E8DB_zpsjcybjynl.jpg

Work your new grommet into the stock grommet hole. If it's anything like mine it will be a very tight fit, but will fit just right. If the parking light wires are not a solid fit, put some shrink tubing on them to raise their diameter like I have done here:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/1E592AAD-E1C8-4424-9572-B67C8B0F0FFC_zpsftcbbv2z.jpg

Cut these connectors off the end of your halos:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/A44031DC-3FE4-4748-A1DD-1E95BBD29BF3_zpsdtklqtgn.jpg

Strip the ends of the halo harness wiring, the ends of the parking light wiring, and if you have led strips the end of those harnesses as well. Put shrink tubing down the parking light wiring (do not heat it) and twist together both or all three wires:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/BC688F45-0CEA-4166-9D99-CA1762A325E9_zpsy6vz2kh8.jpg

Solder the wires if you wish, then pull the shrink tubing over the twists and heat it to seal:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/45AF2A88-3272-4355-89BB-11B1A36E5C8D_zpsgusf7btt.jpg

You now need to repeat these steps for the passenger side, but tie off the stock low beam wiring instead of setting it up to connect; the passenger side low beam stock harness will not be used.

Reinstall the projectors into the reflectors and install the H1 clips as shown:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/7071F794-4C6B-40DE-9939-56925D14E0C5_zpsjphb5ii6.jpg

Next, insert your shrouds, and if you koji modded, I suggest putting a plastic sandwich bag or card stock in between the shrouds and the sides of the reflector to protect the paint.
Then install the reflectors back into the base in the following order for screws: vertical adjustment, horizontal adjustment, top screws, then tighten vertical, make sure to leave access to wires.

Next, alcohol wipe and install the bulbs:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/C0918F6B-7E9B-4D36-A175-1434BCB54667_zps1hiqmpim.jpg

Put on your dust cap and check clearance.

Now we're getting to the car. Use the stock chassis ground for grounding the lights, and put a plastic wall anchor into this hole next to it:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/CE106D58-2956-43A6-9805-4BF589D15BBD_zps58ep0df8.jpg

Install the positive lead onto you battery's accessory post; you will need to slightly drill it out or dremel it to make the hole big enough.  Screw your relay into the wall anchor that you put in, and use industrial strength velcro to mount the ballast if you aren't up for drilling into the chassis:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/DBCD7170-4099-4E0A-8355-1547EA663649_zpsqkjn5wxe.jpg

To run the wiring to the passenger side, I found it easiest to just pop off my radiator shroud and put it through this channel:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/E108F9A9-F22E-4235-B671-57DDA5E20A11_zpskry4fo41.jpg

For those of us with intakes, put a small wall anchor into the old resonator mounting hole, add industrial strength velcro to the ballast, and then secure it with a screw through that wall anchor:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/CC7938EA-8E27-4FC8-B997-06A0ABEA42F1_zpsvrpaswod.jpg

And I anchored the passenger side ground here:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/098C84F0-2EBF-4AA9-B528-9D38866E2253_zps28lo2oco.jpg

Now secure the lights with a couple of bolts each, attach to the ballasts and the stock wiring harness, wire in the LEDs if possible, and fire up and test for shorts:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/1C12D7C2-5C21-4462-A94A-F62AB80DEAD1_zps5oyusate.jpg

Put up something to see how your cutoffs are lining up:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/C098B178-DEEB-4425-8961-0D82596A7671_zpskzukbubq.jpg

As you're adjusting, both with the stock adjustment screws and the washers on the back of the reflector, make sure to put on the dust cap and make sure you don't have too much pressure. If you do, it may be that you'll need to cut out a hole and put a rubber cap in to your dust cap to relieve pressure:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/85415084-515E-4D97-BB61-6023DA90ED58_zpspbdxvv6e.jpg

My main problem with this process was not making sure that I could adjust the light beam completely vertical. I did wind up with a long enough beam, but ideally you should be able to get it to this point. Line up your cutoffs and make sure they're at the same height as the projectors themselves with the vertical adjustment at or near max. if not, try dropping the back of the projector a little in the reflector.
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/6463DC38-E336-48F8-A7ED-95D24D5CD5E5_zpsx6km6tj6.jpg

Once you're happy with fitment, it's time to get to the jb weld. I suggest mixing it in a bowl, and get ready to work fast with a plastic spoon and knife. First off, remove your shroud, then line it with a thick bead of mixed weld that you can push back on and secure into (don't forget to run through the halo wiring into the parking light hole):
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/46DCBFBD-91E9-472F-966B-D78B28B0A143_zpsjcrbjgnc.jpg

For the back of the reflector, you'll need to cut the sides of the silicone washer off with a box knife or X-acto of some kind. This will expose 2 gaps that you can pack plenty of JB Weld into without messing up your original headlight positioning using the back washers and lock nuts:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/CCAB0BA6-59FF-41B1-A1A9-9744BF2BB159_zpssuvensar.jpg
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/EA8FE468-0850-4F9B-8A1E-D52C0E5A35E4_zps1rdodlen.jpg

Allow the JB Weld to set, then fill the seams of your headlight base with the thinned out windshield adhesive:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/408CD20F-8F27-495C-85AE-BF74AD4CB6E0_zpszvasbqrv.jpg

Compress the lens and headlight together, then bake at 200 degrees for 20 minutes. Then put in the screws, press down the edges, turn screws more, press down edges and secure clips, then finally secure screws all the way. Remember to watch your temps, here is the damage I did when my temps were too high and my oven grate was too low, thank god I can cover it with eyelids:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/CFCD392C-9E74-4A7D-870F-5F2B9BB00F72_zpsh2nqrnct.jpg

Now wire up, screw your headlights back into your car and reattach your bumper- you're ready to go:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/040B56A3-FF0D-462B-96CB-C791DAB8E8C9_zpslqrfjfuh.jpg
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/E250E278-AF1D-4EB1-945D-356C4547D28D_zpsonyhakna.jpg
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/7E4B8F9D-1236-43AB-B7AF-A24268D71EBA_zpslsylsrw7.jpg

Headlight control: Since our cars stock use the headlight on lower current as a drl, you'll want to disconnect the drl relay unless you really want your headlights on at all times. I've read many instructions saying that you have to pull the glove compartment, but I put my head under the passenger dash and easily saw and removed this wire harness from the drl relay with no problems:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/B78C2678-8B3F-46AE-8E18-AD358F83B8C2_zpsr8hleoj7.jpg

For the Halos, I am trying to remember to manually switch the parking light switch off and on during the day. The parking light trigger wire used in my alarm has the same effect as just turning the light switch on halfway, so that's not an option. I will probably remove the side marker bulbs and replace the parking light tails with LEDs in case I leave them on on accident.

Last edited by Bradrcr (2014-06-23 16:24:00)


'05 SaaBeeru Areo
'11 WTF(WRX) Hatch
'08 BMW 335i Convertible
'67 Cougar XR7

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#2 2014-05-20 16:25:41

JordanL
Member
From: Vancouver BC | Seattle WA
Registered: 2013-07-08
User Number: 8912
Posts: 83
Website

Re: How to install HID Projectors + almost every other headlight mod

Thanks for the great DIY, Brad. Super informative and explained every detail.  up

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#3 2014-05-22 03:21:14

Bradrcr
Beer Jedi
From: Renton, Wa
Registered: 2012-05-16
User Number: 7247
Posts: 569

Re: How to install HID Projectors + almost every other headlight mod

Addendum:

I did one small mod that gives access to the horizontal adjustment screw if you have the right kind of wrench. For me a duralast (Aurozone) ratcheting wrench was able to reach this even inside the car, although moving the battery and pulling the dust cap was necessary on the drivers side. Not much too it besides cutting down the 'shroud' around the screw:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/4501417B-58B8-4031-9EEE-1127837CE4BD_zpse80ctgzt.jpg

As well, after a couple of days I had to rebake my lights because I did not follow all the instructions above (wrote down what I learned, not what I did in a few parts). In opening to fix my mistakes I also decided to black out ALL of my chrome since I didn't like the pattern of coloring across my light. I also put back my stock reflectors and gave the LED a light dusting of paint spray, with very pleasing results:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/4A4D4EF9-8E7D-4BB8-A8F4-7C6F17F18817_zps8awyqxoy.jpg

http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/508F8EC4-1E2E-477A-8291-4DBB23E311E8_zpsuwqrcioh.jpg

http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/0B0E24CF-D0E4-4D2B-9336-2D2DEDEF24E8_zpsecpa5u13.jpg


'05 SaaBeeru Areo
'11 WTF(WRX) Hatch
'08 BMW 335i Convertible
'67 Cougar XR7

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#4 2014-05-26 15:08:00

venZon
Member
Registered: 2014-01-23
User Number: 13784
Posts: 67

Re: How to install HID Projectors + almost every other headlight mod

How long did it take you?  Thanks for doing this write up!

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#5 2014-05-30 23:16:29

Bradrcr
Beer Jedi
From: Renton, Wa
Registered: 2012-05-16
User Number: 7247
Posts: 569

Re: How to install HID Projectors + almost every other headlight mod

venZon wrote:

How long did it take you?  Thanks for doing this write up!

I spent a full weekend on it. I'd guess most people could get through it in a day, especially if they're not doing many of the optional steps.


'05 SaaBeeru Areo
'11 WTF(WRX) Hatch
'08 BMW 335i Convertible
'67 Cougar XR7

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#6 2014-06-23 13:02:23

dcm220
Member
Registered: 2013-10-28
User Number: 11952
Posts: 18

Re: How to install HID Projectors + almost every other headlight mod

Nice write-up.

I attempted to install the TRS Mini H1 kit this weekend (bought during the Black Friday 2013 sale).  I say attempted, because after I reassembled the headlight housing, the shroud (Apollo 3.0) contacted the clear lens. mad  The shroud was knocked loose on one, and neither one has vertical adjustability because of the interference.  So I need to go back and set the projector farther back in the reflector. 

How did you attach the projector to the reflector?  Is it just the JB Weld?  Or is the nut holding the washer/backing-plate?

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#7 2014-06-23 13:06:20

Bradrcr
Beer Jedi
From: Renton, Wa
Registered: 2012-05-16
User Number: 7247
Posts: 569

Re: How to install HID Projectors + almost every other headlight mod

I actually attached using both to the reflector. On some of the shrouds it may be hard/next to impossible to get them on. I think it may work if you 'hollow out' some of the plastic inside the shrouds.


'05 SaaBeeru Areo
'11 WTF(WRX) Hatch
'08 BMW 335i Convertible
'67 Cougar XR7

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#8 2014-06-23 15:58:30

b00duh
Member
From: Winnipeg, MB, Canada
Registered: 2008-12-13
User Number: 3387
Posts: 1343

Re: How to install HID Projectors + almost every other headlight mod

dcm220 wrote:

Nice write-up.

I attempted to install the TRS Mini H1 kit this weekend (bought during the Black Friday 2013 sale).  I say attempted, because after I reassembled the headlight housing, the shroud (Apollo 3.0) contacted the clear lens. mad  The shroud was knocked loose on one, and neither one has vertical adjustability because of the interference.  So I need to go back and set the projector farther back in the reflector. 

How did you attach the projector to the reflector?  Is it just the JB Weld?  Or is the nut holding the washer/backing-plate?

I am running the same setup as you.  I had to do some major modifications to use those lenses with my headlights.  Trimmed half the shroud off and had to make the lens sit far back into the headlight so it wouldn't make contact with the clear lens.  I used JB weld and discarded the nut and rubber washer that came with the lenses because they were useless with the amount of the reflector bowl I had to take off.


2005 Saabaru 9-2x Linear
Specs: arctic silver/5mt/cold weather package/sunroof

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#9 2014-06-24 16:36:32

dcm220
Member
Registered: 2013-10-28
User Number: 11952
Posts: 18

Re: How to install HID Projectors + almost every other headlight mod

Bradrcr & b00duh, thanks for the info.  When applying the JB Weld, did you just do it from the rear, on the backside of the reflector bowl, like in the two pictures below?  Or did you apply more somewhere to keep it from becoming loose?  b00duh, did you use the Apollo 3.0 shrouds?  Any pictures?

Bradrcr wrote:

For the back of the reflector, you'll need to cut the sides of the silicone washer off with a box knife or X-acto of some kind. This will expose 2 gaps that you can pack plenty of JB Weld into without messing up your original headlight positioning using the back washers and lock nuts:
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/CCAB0BA6-59FF-41B1-A1A9-9744BF2BB159_zpssuvensar.jpg
http://i1162.photobucket.com/albums/q522/Bradrcr/SaaBeeru/HID%20How%20To/EA8FE468-0850-4F9B-8A1E-D52C0E5A35E4_zps1rdodlen.jpg

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#10 2014-06-24 16:50:57

Bradrcr
Beer Jedi
From: Renton, Wa
Registered: 2012-05-16
User Number: 7247
Posts: 569

Re: How to install HID Projectors + almost every other headlight mod

I just put mine on the sides and it was VERY secure. If you press JB weld into those gaps you should get a bit to secure the sides of the projector to the back of the reflector, or you could try adding some from the front I guess, but it shouldn't be necessary.


'05 SaaBeeru Areo
'11 WTF(WRX) Hatch
'08 BMW 335i Convertible
'67 Cougar XR7

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#11 2016-06-09 11:31:41

robrob
Member
From: Seattle WA
Registered: 2015-07-21
User Number: 32425
Posts: 36

Re: How to install HID Projectors + almost every other headlight mod

Is this using the halogen or hid housings?

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#12 2016-06-09 13:31:33

Bradrcr
Beer Jedi
From: Renton, Wa
Registered: 2012-05-16
User Number: 7247
Posts: 569

Re: How to install HID Projectors + almost every other headlight mod

This is using the Halogens, but from what I've seen of the HID housings, it would likely work the same.


'05 SaaBeeru Areo
'11 WTF(WRX) Hatch
'08 BMW 335i Convertible
'67 Cougar XR7

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