Bixenon Projector Mod

[chaingun427]

So, i HATE my HIDs anymore. The ridiculous amount of glare, and poor focus have driven me to the point I wanted to go back to normal Halogen bulbs. I had a suggestion to try a set of Projector headlights from Ebay, and while they look better than the stock Halogen low beams. the high beams are terrible and the low beam pattern is inconsistent as all hell.

The weakest point of these trucks to me has always been the forward lighting, so i was at a loss and figured what the hell lets grab some aftermarket projectors and see what i could do!

To begin i picked up this set of headlights http://www.ebay.com/itm/88-98-Chevy-GMC-Silverado-Suburban-Tahoe-C10-C-K-Halo-LED-Projector-Headlight-/331163047111?fits=Make:Chevrolet&hash=item4d1adb14c7:g:SWcAAOSwAYtWIaLO&vxp=mtr
which produced this spectacular beam pattern above

and these projectors http://ddmtuning.com/Products/Projectors-H1-V3-PR
The golden standard Morimoto Mini H1 might work as well, however my initial contacts to Theretrofitsource put them on the edge of being too large.

Removing all the fittings, screws, etc, to open the lenses, i set my oven at 270*, popped them in for 10 minutes, and then carefully pried them open with a butter knife.
the inner black shield comes out easily enough, if you plan to use them I'd use this opportunity to swap the LEDS to better ones as they tend to burn out fairly quickly. I don't plan to use them so i left them alone.
removing the shield and reflector on the back leaves a bare lens and retainer as shown here.
continued on next post dang 5 pic limit

 

[chaingun427]

removing the screws on the metal ring allows the removal of the lens as well WOO bare housing!

the next step involves our good friend Mr Dremel! first we cut off the top of the old lens retainer

and bore out the inside a bit to accept the new projector lens.

after boring, you should be able to slip the lens and bracket into the housing

The big deal about a bixenon projector is that the hi and low beam are contained in the same housing, with a shutter to change them over. That shutter requires a notch around the solenoid to fit into the housing.

 

[chaingun427]

with the shutter fitted, we can start on the bowl, not the extreme differences between the two, DDM tuning on the left, craptastic ebay special on the right. also, note the spacing of the holes, which is what makes this whole thing work as well as it does.

I used some machine screws from a multipack deal from wally world, fitted to the bowl, they're just a bit bigger than the hole so i could have either wallowed the holes out, or do what i did, which was just to run them through to cut the threads into the holes so they were tighter.

tighten them down and seal with your sealant of choice, as these are my test set i temporarily sealed them with heat tape, to be replaced later with something more permenant.

 

[chaingun427]

replacing the inner panel should see it fit like the original lens, making them visually no different than the stock projectors when installed.
resealing the lights for me consisted of removing as much of the original sealant as possible, and stuffing the crack with new butyl rubber, heating it again in the oven, and pressing it together CAREFULLY but forcefully and reattaching the clips that go around the outer lens.

it look me forever to get around to getting them installed since i was in the middle of on LS swap at the time.

Now that their in, albiet not fully aimed, i'm very very happy with the change

55w 5000k HID H1 style
Low beam:

High Beam:


compared to this asstastic setup with QUAD 55w 9005/9006 6000k HIDs


long story short, i plan on updating these more, and finishing the recess kit for my phantom grill kit, but at least i can see my way forward now!

 

[DallasTahoe]

Nice write up! I'm diggin the light pattern! I think I'll be doing the same pretty soon, I've got a hid kit but took it off, just running stocks now.


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[DallasTahoe]

Oh yea and how is the wiring into the harness? Plug and play or is there some splicing involved?


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[chaingun427]

Standard 4 hi mod, with a relay for low beam power as well. I used hella solid state relays to prevent flicker

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