I've been looking into this for awhile and have found many sources and i can say that i can do this job.
This is my plans for the retrofit:
S2000 or TSX Low Beams (very similar to each other) s2000 seems to be better
TL Fogs/HighBeams
CCFL Clearance Lights
Blacked out housing
Cleared out turn signals

Now with questions:
1. How to seal the back of the projector if the stock dust cap was cut off.
2. How do you aim Quad Projectors?
3. do you still use the stock reflectors?
4. the stock Fog/high bulbs are H4 but will be changing it to D2s bulbs and how do i convert a h4 female to a d2s female?
5. What would happen if i mounted the projector so far up that the projector almost hits the front lense and have the centers blacked out too with HIGH temperature paint? first of all it gives me more width

 

"I've been able to mount the TSX's with no modification needed to the back dust caps. But in order to do this, I had to mount them to the stock reflectors, and modify the TSX's with a custom shroud, so it won't look funny. That took a 1 month to do on my schedule." By E_K
http://danielsternlighting.com/tech/aim/aim.html
Seems like giberish to me

Wrah's Thread
https://g35driver.com/forums/lighting/59543-wrah-s-custom-projectors.html

PeteNJ CCFL Tube clearance Strip DIY
https://g35driver.com/forums/body-interior-exterior-lighting-diy/75227-diy-ccfl-clearance-strips.html

PeteNJ Actual Projector RetroFit DIY
https://g35driver.com/forums/body-interior-exterior-lighting-diy/75211-diy-projector-retrofit.html

One of my original threads
https://g35driver.com/forums/lighting/78061-retrofit-2006-headlights-then-sell-mine.html

Some Extra Information
https://g35driver.com/forums/interior-exterior/64432-wanted-projector-retro-fit-diy.html

Please keep this strictly references to DIY Retrofit Questions

 

Well, on a project I did, that wasn't a g35. I painted a peanutbutter jar black and used the screw of lids for the back dust cover. On the G35 you could do the same, but you have about 2" max because of the finder.

On quad projectors you mount your low-beam then aim your high. They are both fixed to the same bracket, so just make sure your highbeam is shooting down the road correctly when your low beam is where you want it. Mounting to the OEM adjustment bracket means you can make changes later.

You don't have to, I didn't.

If you are going with quad-projectors, then you don't need to worry about h4 bulbs. You should be using D2s.

Don't mount too far forward. The heat won't melt your lense but it might smoke/fog/fume. There's really no advantage to mounting that far forward anyway, you width isn't cut down that much.

 

3. do you still use the stock reflectors?

4. the stock Fog/high bulbs are H4 but will be changing it to D2s bulbs and how do i convert a h4 female to a d2s female?
i mean there is something that tells this light that it works a certain way well there is a d2s bulbs and a d2s bulb is not the same as the h4. sooo it isn't really plug and play do i need some kind of wiring harness?

 

Good choices. Almost the same thing I'm doing:
TSX low beam
TL fog/high with clear lenses
CCFL clearance
cleared signal with clear reflector

I'm keeping the bezel chrome, since I've done black housings before, and personally I want it to look OEM. It's also more challenging to polish metal to match the chrome than spray painting it. But it would look meaner with black bezels.



1. How to seal the back of the projector if the stock dust cap was cut off.

There's about 10 ways to do it. Most people use a combination of plastic containers, JB weld, silicone, or Nissan black sealant.

2. How do you aim Quad Projectors?
Same as any other setup. Depends on how you mount it. I usually use 2 bolts to secure the projector, and a 3rd bolt is used as the adjustment bolt.

The extra step with quad projectors is trying to line the Z cutoff from the bottom projector to match up with the top one.


3. do you still use the stock reflectors?
Depends on how you like to retrofit. With E46 projectors you don't need the stock reflectors, because the mounting holes can be matched to the metal bracket. With TSX projectors, you have to use the reflector, otherwise the bolts will be hanging in mid air. I didn't use the reflector to mount the TLs.

4. the stock Fog/high bulbs are H4 but will be changing it to D2s bulbs and how do i convert a h4 female to a d2s female?

This step will give you a hard time if you're not familiar with how the lights work.

The stock H4 has two filaments. One filament lights up for the fog light. When you turn on the high beam, filament #1 turns OFF, filament #2 comes on.

A DS2 or D2R bulb is essentially on or off. Not dual filament.

The H4 plug has 3 wires. One is + for fog. One is + for high. One is ground or negative.

HID plug is two wires. One is +, one is -.

Here's your problem. You could easily cut the H4 connector and hook the wires to a HID plug. But which + wire do you use? The fog or the high?

No matter which one you use, you're going to lose either the fog or the high beam.

Let's say you get a bixenon projector for the fog/high. You'd hook the fog + to the HID + wire, and the negatives together. You hook the high beam + wire to the + of the solenoid. You might want to put a resistor in there to drop the voltage to the solenoid down to about 9 volts, to prevent it from overheating.

But remember that filament #1 (fog) turns off once you activate the high beam (filament #2). So you could get the bottom projector to light up for the fog, but once you switch on your high beam, the solenoid moves the shield, but the HID is OFF now.

There are two solutions that I know of:

1. Buy an H4 wiring harness that will allow both filaments to be on at the same time. I haven't found an online source for this. I bought one at hidforum a while back, and I've never seen another one for sale. Or ask someone on that forum to make you one.

2. If you're good with diodes and relays (I'm not), you could do the wiring yourself to keep both filaments on. I think you just have to stick a diode between the + of the high and + of the low beam.



5. What would happen if i mounted the projector so far up that the projector almost hits the front lense and have the centers blacked out too with HIGH temperature paint? first of all it gives me more width

With the way the G35 headlight is designed, I don't think you'll have a problem with them being too far forward. Chances are you'll have problems in the rear dust cap. Make sure you use high temp paint for the bezel. And sand that thing first, to help the paint stick better.

Good luck with the project. You'll also have to get creative in making shrouds to make everything look nice. For every question that you get answered for a project like this, 3 more come up. Please read up on hidforum.com. Some off the stuff that I've accumulated over the past 3 months for this project are things that I've rarely ever seen offered for sale. Like the purple tinted clear lenses that I got to fit the TL, and the wiring harness that will allow both high/fog to be on at the same time. That's one reason why I don't think I could ever reproduce this project for someone else.


edited better info on diodes.

 

does anyone know if the lenses in a tl and tsx projectors are VERY clear or not. is there something i can change to that will make them "clearer"

 

Keep in mind, when you swap lenses, you're not just looking at lenses of the same diameter. You also need to take into account the focal length.

With that said, TSX is fairly clear. No fresnel lines, very very slight texturing, but you have to really look for it. S2000 is apparently more clear, but is slightly larger than TSX, and per hidforum, not interchangeable. I wouldn't bother trying to change the TSX lenses. You can achieve better sharpness with a shield that doesn't have the double shield going on (you'll know what I mean if you have a TSX projector).

TL is fresnel. Definitely not what most people would call a "clear" lens, but better than most fresnel lenses. The direct replacement clear lens is from the ZKW Bixenon. But those are pretty rare. One retrofitter on hidforum gets them for $200, and then upgrades the TLs for his clients. Meaning, add $200 to the price of a retrofit for clear lenses on your TLs. Don't get the E46 Bixenons with the line in the middle. They're not fresnel, but apparently have so much texturing that they're worse than a good fresnel lens.

I put H3 halogen projector clear lenses onto my TLs, that I got for $30. These are common lenses found in those TYC/APC aftermarket housings with horrible outputs. But the lenses are pretty good. The ones I got from another retrofitter had purple tint on them. He gets his lenses from the aftermarket Maxima headlights. They actually shine a bit purple when looking at the headlight, but the light on the ground is still white.

Those lenses were even clearer than the TSX ones. The one that I used on the driver side had no texturing. But they are 2 mm larger than the TL fresnel lenses, so you'll have to do serious modification to make them fit. Plus the focal length is off. I managed to fit them using RS6 bixenon lens holders:

You can see how "clear" these lenses are. You can also see how much modification I did to the TSX and TL projectors. Results are definitely worth it though.

 

E_K & WRAH..... you guys rock on these retro-fit..... you know, you can make a killing on these.... just quit your normal job and mass produce these puppies.... they are absolutely better then the 06 projectors hands down...... so what do you guys say....? i'll be first in line to buy!!!!!

 

lol, I think my day job would still end up paying better. I knew about 2 months into this project, that I would not be able to reproduce this for anyone else.

 

Yeah, making these wouldn't even pay my health benefits.

 

do you guys think i can put s2000 projectors in here?

 

I would forget s2000 projectors. The old ones with the best light are a major PITA to work with. (You have to cut the metal down and mod the projector itself to make it fit) The new s2000 aren't any better than TSX, which is ALOT cheaper!

I say go TSX projectors for single xenon, you will be very happy.

 

This is a specific question for E_k.

where did you get the following.
high temp primer, high temp gloss black, and high temp clearcoat?

 

pepboys, or any autoparts store. Just get the engine enamel. One can of each will be good for 6 headlights easily. Sand the bezel with 400+ sandpaper, then wipe/rinse/blow off the dust, and spray in an area that is as dustfree as possible (with good ventilation of course).

 

How are the clear turn signals done?