So after over a month and 50+ hours working on this headlight I finally finished. I am happy with the output but not as satisfied on the how the trim came out. The heat from the projector made the polished cans warp a tad (Probably becuase of me using JB Kwik instead of JB Weld to fasten them). You can't notice it unless you look really closely but I will probably fix it one day. Anyways, here are some teaser pics until I can writeup the DIY:

Closeup of Driverside:


Output Wallshot:



Parking Lights in action (CCFL in clearance, Custom LED Clear corner lights):



Would I do this again? Absolutely not.

I've been following your posts on hidplanet.com and i've got to hand it to ya, you are really informative and handy when it comes to lighting. With that said, nice job on the projectors! I love the color band of blue that it puts out, not to mention the CCFL setup in the clearance strip..thats hot!

Sure you will! When I come over and you hook me up. What trim did you end up using?

Finally, heh...looks like a good cutoff. Can you get a close up of your shroud?

Having done 3 retrofits now, and working on the 4th again for myself, it can get really tiring doing these. It's been about 3 weeks now, and I'm only 30% done with my next retrofit. Maybe I'll post a preview pic in another thread...

Edit: oh yeah, one more thing. It's probably the JB Qwik that melted. It has a lower temperature rating than JB Weld. The melting point of aluminum is much higher than the temp of a HID bulb, so I don't think the aluminum itself really warped or melted.

very nice job~!!

I love it! I can't wait for the how-to write up. Maybe you can give a list of the componenst and supplies, as wel as where you got them.

I agree. This is the most creative project I have seen done with ccfl and projectors.

GOOD WORK!

Excellent work PeteNJ, Congrats

nice work, looks like a lot of patients to do this

Haha...ill help. In fact if I had to do it over again I am sure I could do it much quicker and better. I learned a lot doing this but it was a lot of work. I ended up using polished cans.

I will get a closeup shot this weekend. I cant during the week since I leave for work real early and come home in the dark. BTW, on all your retros you painted the inner part of the chrome headlight shroud right? I think I may do this when I fix the trim in a few months. There is a scootch of glare coming from the side.

I can't take credit for the ideas. The CCFL idea came from a retro I saw on hidretro.com The polished can trim idea is from E_K.

I painted the bottom part of the bezel. I'm trying to remedy the glare issue without having to use paint for my next retro project. Otherwise you get some glare from the headlight when you're standing about 5-6 feet above ground.

So you're going to go back in? After I finished mine, I swore that I wouldn't go back in, but it's happened about 5 times now. Hopefully this last time will be the last, so that's why I'm just taking my time working on my own lights.

any daytime pic for CCFL??

+1...