ULTIMATE HEADLIGHT UPGRADE: FX-R projector retrofit in progress, with pics

Arnel · May 7, 2009

I've had an HID kit from Xenondepot installed for 2yrs now (OEM ballasts, 35w, relay harness, 4300k bulbs). Since the Ody uses a reflector based headlight there is a slight amount of glare, but because I have the lights aimed low, I've only been flashed a couple times only when the vehicle was stopped on a large incline, and oncoming drivers stopped across the intersection were below the cutoff (which still happens even with OEM self leveling HID's, if the incline grade is high enough).

Mainly, the poor spread, beam pattern, hotspots, and cutoff is the reason I'm retrofitting projectors. I plan to do one at a time, so an A/B comparison is possible.

Here's the breakdown:

* FX-R bi-xenon projectors from The Retrofit Source $180
* Gatling Gun shrouds from TRS $50
* AMP to D2S adapters from TRS (thanks Matt)
* Phillips 85122 OEM bulbs, 4300k (already had these, otherwise ~55pr)
* May upgrade to DDM 55w ballasts, depending on the outcome

These arrived today:

I'm hoping to get started over the weekend. Since I didn't purchase spare lights, it may be a rush job done at night while the family is asleep. Hopefully this will go smoothly.

More progress pics to follow.

edit: final output shots on pg 3

djmdx2 · May 7, 2009

Nice! Been planning this for a year. The FX bixenons have been sitting in my garage for a year!

Good tip on the shrouds. Post up more pics of the output!

Arnel · May 8, 2009

djmdx2 said:
Nice! Been planning this for a year. The FX bixenons have been sitting in my garage for a year!

Good tip on the shrouds. Post up more pics of the output!

LOL, I know the feeling. I've got all kinds of suspension bushings for the other car that have collected dust for 2yrs, along with light fixtures for the house, etc, etc, etc, all waiting to be installed.

Are your FX35 projectors OEM or replica? If OEM, you'll be interested in FX replica clear lenses, or TSX replica lens and a shield mod. However, if you've had a year to sit on these, you probably already know this

Here's a comparison between the OEM FX and FX-R:

tC_demon · May 8, 2009

COOOL! Can't wait for the finish product!!!!! Subscribe.

I have a pair of a 2007 IS headlights (got into a accident with the Lexus) Are the projectors big engouh for the ODY?

Arnel · May 8, 2009

I'm not familiar with the size of the IS250 projectors, but I'm sure they're no smaller than FX, which are amongst the smaller projectors. So I'm sure they're "big enough". Most have problem with projectors being too big. Plenty of room in the Ody headlight, enough to fit higher end (and larger) projectors like the ls430. Out of my budget though.

Before you commit to starting the labor, I'd take a look at some projector comparisons on HIDplanet.com. Username JVX has a few threads with comparison photos. IIRC, the IS250 and e46 projectors were less desirable due to lack of width and intensity. You don't want to go thru all that labor only to be less than happy with the results.

tC_demon · May 8, 2009

What will you use to hold the projector and shroud together and on to the housing?

Arnel · May 8, 2009

I still haven't decided yet...not too many pics of Ody retrofits to borrow ideas from. I will likely use long screws or threaded rod and springs for the projector.

As for the shroud, never worked with one before...last retrofit on e36 BMW/Depo headlights, I just reused internal parts. I was hoping it would snap on, but no. Going to give Matt at TRS a call, and search on HIDplanet for ideas. Suggestions welcome.

famman · May 8, 2009

Arnel said:
I still haven't decided yet...not too many pics of Ody retrofits to borrow ideas from. I will likely use long screws or threaded rod and springs for the projector.

As for the shroud, never worked with one before...last retrofit on e36 BMW/Depo headlights, I just reused internal parts. I was hoping it would snap on, but no. Going to give Matt at TRS a call, and search on HIDplanet for ideas. Suggestions welcome.

Can't wait to see the final product! Good luck with the install. If you are interested in upgrading the rims and tires, let me know. I'm your man... and practically live a few miles from you. Happy to help out any way I can!

eneka1 · May 8, 2009

subscribed

Arnel · May 8, 2009

famman said:
If you are interested in upgrading the rims and tires, let me know. I'm your man... and practically live a few miles from you. Happy to help out any way I can!

Thanks, but luckily the "rims and tires" syndrome has not hit me with this particular vehicle

...just can't justify the expense, and I'm sure the wife will agree. Got the ok on the retro due to bad night vision. If we get bitten by the wheel bug, I now know who to contact.

BTW, I like your sig. It's not against the TOS here? If not, I'm making a shameless plug in mine

nstygrnhatch · May 8, 2009

Let us know how it turns out, i would like to see the finished product!

dvpatel · May 8, 2009

Arnel said:
BTW, I like your sig. It's not against the TOS here? If not, I'm making a shameless plug in mine

Well, it kind of is against the rules. Per the rules, Jim wants ALL vendors (aka dealers) to contact him and get his permission before posting their stuff. But, Jim is mostly MIA. So, the vending has become kind of free for all.

The original intent of Jim was to NOT have free for all.

And yes, as helpful as famman is, I personally still consider bulk selling even by members as vending. Normal users would only have one or two items vendors would have multiples.

It would be nice if the plugs were not in the sigs but with Jim's absense, do what you guys feel is the right thing to do.

famman · May 8, 2009

dvpatel said:
Well, it kind of is against the rules. Per the rules, Jim wants ALL vendors (aka dealers) to contact him and get his permission before posting their stuff. But, Jim is mostly MIA. So, the vending has become kind of free for all.

The original intent of Jim was to NOT have free for all.

And yes, as helpful as famman is, I personally still consider bulk selling even by members as vending. Normal users would only have one or two items vendors would have multiples.

It would be nice if the plugs were not in the sigs but with Jim's absense, do what you guys feel is the right thing to do.

Appreciate it dvpatel. While I wouldn't classify myself as a vendor since this isn't my fulltime gig... I can understand other aspects of your response.

You gotta think sorta that anyone that helps others get rid of their PAX nightmare... should practically be considered a saint and a friend to all Ody owners everywhere!

dvpatel · May 8, 2009

famman said:
Appreciate it dvpatel. While I wouldn't classify myself as a vendor since this isn't my fulltime gig... I can understand other aspects of your response.

You gotta think sorta that anyone that helps others get rid of their PAX nightmare... should practically be considered a saint and a friend to all Ody owners everywhere!

At most forums, if you sell multiple sets of Wheel upgrades, you'd be classified as a vendor. I am not sure why you think otherwise. Regardless of if you do this full time or not, selling tens of sets is vending.

As to being a saint/friend, I'd consider you that if you start selling them wheels "at cost". Surely you are not prividing the dePax service "at cost" right.

In any case, like I said, Jim's not here for now and this being his site, he can chose to clasify you and Mike as normal user(s) or vendors. Fine by me in either case.

And yes, I have sold about 6 - 8 Accord In-Dash CD Changers on here back in 2002 so I would know what's vending and what's normal selling.

Any way, lets get back to projector retrofits.

clanton1.8T · May 9, 2009

looking forward to see the progress

mik911 · May 9, 2009

Keep us updated.
interested in how you mount them.
the cutoff is insane!

akaBobbys2k · May 12, 2009

subscribed.

Very interested in the outcome of your project.

thanks.

Arnel · May 12, 2009

Driver's side done, for now.

Update:
I was able to get some work done on the driver's side last night. Admittedly, this was a rushed job, as I had to get it done and get the bumper back on so the vehicle could be used this morning. I finished up around midnight, and it was getting in the 40's. I have a heated garage, but had to work with the door open to give room to work on the bumper. I'm not 100% satisfied, so I'll have to open it back up when I get time.

Instructions/timeframe:
~15m remove bumper, remove L headlight assembly
~6m bake headlight at 170deg
~10m rebake headlight at 225 (170 for 6m was not enough to soften glue)
~15m to separate lens from headlight
~10m to dremel hole in reflector using tile cutting bit
~4hrs to line up & drill screw holes, mount, aim, test drive, re-aim, tighten, break the reflector due to overtightening since my regular drill with 16tq settings was unavailable

, glue reflector, remount, re-aim, test drive, glue screws to prevent movement
~10m glue Gatling Gun shroud (I was tired at this point and just wanted to finish, I should have trimmed the back of the shroud so the projector lens isn't so recessed)
~20m reseal headlight assembly. Sitting in the cold, the OEM glue got stiff...had to rebake at 220 for 5m
~20m reinstall headlight, reinstall bumper, recheck aim

Aiming by far was the most difficult process. The Ody headlight assembly only has horizontal adjustment, so the "step/uptick" had to be vertically aimed, and horizontal had to match highbeam. I decided to mount the assembly (without lens cover) to the car and shine it on the wall to aim.

My Xenondepot kit that uses OEM Phillips ballasts does not use AMP connectors that match my AMP-D2S adapters. I had 2 sets of ballasts sitting in the garage...an old 35w Prolumen kit from 05, or a new 35w DDM Raptor digital slim ballast kit. I used the Raptor kit.

*****NOTE, XENONDEPOT KIT WILL BE FOR SALE IF ANYONE'S INTERESTED. This is a quality kit using Phillips ballasts, ignitors & Phillips 4300k bulbs with harness (separately fused w/individulal relays). I paid $379.99 shipped and installed it on 3-07. Unsure of current pricing. Open to offers.******

Oh, and here are the pics...comments, suggestions, constructive criticism welcome

:

FX-R projector prior to drilling mount holes. Notice the horiz/vert lines which help aiming. I just ended up using a small spirit level and aiming while mounted to vehicle and illuminated on wall

Can see the 1.75" #8 screws, star washers, and nuts

Arnel · May 12, 2009

Bolted in, shroud glue drying

Shroud needs trimming from the backside so lens is not so countersunk

. How bad does this look?

Arnel · May 12, 2009

Output shots:

Before at ~25', OEM reflector w/XD 35w 4300k, poor cutoff, and bright hotspot in center.

After. FX-R w/DDM Raptor 35w ballast, 3yr old 85122 D2S bulb. Look at the sharp cutoff (sorry about blurry image, point & shoot camera w/o tripod)

OEM 100ft (notice the light has limited width, left side of parking lot completely black)

FX-R 100ft. Although output *appears* dimmer without hotspot, notice how much more evenly distributed the light is, illuminating ground areas that the reflector did not. The width extends beyond the width of the camera (and these projectors are not known for being "wide" like ls430.

combined 25':

combined left FX-R, right OEM. ~12' from wall. See the glare "altar" shaped area above the R beam? This is what everyone is referring to about glare using HID's w/OEM reflector headlights.

highbeams

cutoff at ~30ft. The blue "flicker" is desirable among retrofitters, but I'm indifferent about it. The blue looks cool, but just calls more attention to state troopers hiding in speedtraps IMO.

Remaining todo's:
Reopen headlight, trim shroud.
Remove Xenondepot kit
Install new harness
Possibly upgrade to 55w ballast
Install passenger side projector
Wire bi-xenon solenoids

Hope to resume in 2wks.

Phew....it took a long time to finish this post. Hope it helps someone.

eneka1 · May 12, 2009

wow looks really nice..i just might do it someday when i get the time. after having xenons on our e46 and light on the ody always seem dim..

Arnel · May 12, 2009

eneka1 said:
wow looks really nice..i just might do it someday when i get the time. after having xenons on our e46 and light on the ody always seem dim..

Thanks. And BTW, DO IT!

We had an 01 330i w/xenon, and the output was narrow with soft cutoff. The FX-R projectors (or TSX, LS430, SC430, TL, RX-AFS, S2K) are all much better than e46. You won't be disappointed.

djmdx2 · May 12, 2009

Again, great post. The shroud doesn't look that bad. Nice cutoff. I gotta do this soon.

Arnel · May 12, 2009

djmdx2 said:
The shroud doesn't look that bad.

You don't think so? I'm 50/50 on it, but I was fine with it at 12am last night when it was a cold 45 deg in the garage, and I wanted to finish

.

I just got back taking a late night cruise to admire the new cutoff. It appears in my haste, I did not get the aiming perfect...the cutoff slopes clockwise by 2-3 degrees. Looks like it's coming apart regardless, and I've got to remove all the goop I dabbed over the screws/nuts to hold them in place.

I can see why some retrofitters will charge $600-800 to do this. My e36 M3 headlights were much easier to work on.

mik911 · May 14, 2009

Very impressive work!!
That cutoff is da bomb.
You should offer a 'kit' or converted assemblies. I'd buy one.

Arnel · May 14, 2009

mik911 said:
Very impressive work!!
That cutoff is da bomb.
You should offer a 'kit' or converted assemblies. I'd buy one.

Thanks for the kind words. Funny, I was thinking the same thing. Wife just lost a great job making good $ working from home, and I need to supplement income

. I used to install alarms and remote starters on the side 15-20yrs ago for $100 profit for 2-5hrs work. Now that I've done this, I know the 2nd one will go much easier than the 6hrs it took for only 1 side. I'm thinking 4-5hrs total and it's fun to do.

The problem is after factoring in all the costs involved, and time spent, people would either not want to spend the $ for what I'd need to charge to make it worthwhile, esp after factoring in how easy it is to break a headlight while baking & separating, or drop a projector, potentially eroding any profit. I think I'll stick to my day job, and leave this to the professional retrofitters

ULTIMATE HEADLIGHT UPGRADE: FX-R projector retrofit in progress, with pics

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