DIY: Morimoto Mini H1 Bi-xenon projector retrofit

I've had a bunch of requests for a DIY guide on my retrofit, so here it is.

 

Parts required:

2 piece USDM headlights and corners

Morimoto Mini H1 projectors

Mini gatling shrouds

Motocontrol harness [match your car's factory headlight plug]

HID ballasts and H1 bulbs

Headlight sealant [butyl rubber - OEM nissan, Koito, or 3M window weld ribbon]

Kydex sheet

 

Tools required:

Dremel

Reinforced cutting wheels

Screwdriver set

Oven [Heat gun if you're a scaredy cat. Just man up and use the oven, dammit.]

Oven thermometer [Never trust the built in temp display. Some ovens are not good at regulating low temps.]

Gloves

Epoxy or adhesive sealant

Paint

 

Bench testing bi-xenon solenoids

This is very important, you need to make sure the solenoid that flips the cutoff shield down for high beams is working flawlessly. Sometimes you might have a sticky plunger, or weak spring. Use a 12v power source to cycle it at LEAST 50 times. You will hear it click, but make sure you actually watch the shield move. If everything's working, great! Get to work you bums.

 

Splitting the headlights and corners

Preheat your oven to 210°F. Remove all bulbs, screws, and the four clips on each headlight housing. Place a flat baking sheet in the oven. I baked the headlight housings for 12 minutes and the corners for 7 minutes. To split the baked headlights, stick a butter knife or flat head screwdriver between the headlight lens and housing. Gently give it a twist to start opening the gap, and work your way around the lens. Once you have a gap, you can pull them apart by hand. To split the corners, you will have to pry them apart with the prying tool of your choice. The corner light lens slides out toward the front of the car, not straight off the lens. Keep the tabs in mind, and do not pry too hard or you will crack the lens.

 

Cutting and trimming the headlight housings

Remove the bulb shields. There's a small cover that clips on over the mounting screw for the shields. Pull out the wire headlight bulb holder as well. You will need to use your dremel with the cutting wheel to cut down the bulb holder on the housing. Here's a photo of what the bulb socket looked like after I cut it:

 

http://i489.photobucket.com/albums/rr260/TurboThom/1997%20OB/USDM%20Retrofit/Locking-nut_zpsbcf095ed.jpg

 

You will need to cut a hole in the bottom of the housing to clear the bottom of the projector, and cut off the area the stock bulb shields screwed into.

 

http://i489.photobucket.com/albums/rr260/TurboThom/1997%20OB/USDM%20Retrofit/Housing-hole_zps781e1b48.jpg

 

You will need to trim the bottom of your shrouds to clear the housing. I didn't get any photos of that, but you're schmart peoples and I have no doubt that you can figure it out. I don't want to see any posts saying "Directions unclear, penis is stuck in ceiling fan. Please send help."

 

Painting

Strip the chrome from everything you intend to paint, either chemically or via sanding. I used Glad Press n Seal to mask off a chrome ring on the ends of my shrouds when I painted them, and did the same thing when I masked off the turn signal reflectors in the corner lights. Lightly press down just enough to seal, then trim with a razor.

 

http://i489.photobucket.com/albums/rr260/TurboThom/1997%20OB/USDM%20Retrofit/Corner-mask_zps96fa4e1f.jpg

http://i489.photobucket.com/albums/rr260/TurboThom/1997%20OB/USDM%20Retrofit/Corner-painted_zps5e0fecaf.jpg

 

Mounting the projectors

These projectors mount really easy, you should only need to adjust rotation. Run the bi-xenon wires through the hole you cut at the bottom of the housing.

 

Projector reflector bowl | Small silicone washer | Headlight housing | Metal washer | Lock nut | Bulb holder

 

http://i489.photobucket.com/albums/rr260/TurboThom/1997%20OB/USDM%20Retrofit/Locking-nut_zpsbcf095ed.jpg

 

Don't crank down the locking nut. Make it tight, but so that you can still rotate the projector with a bit of force. Put your headlights on the car and adjust the rotation so the cutoff is level, and then lock down the nut good and tight so the projector is locked in place. The wiring harness is plug and play, I don't think I need to write a section for the wiring or HID install.

 

http://i489.photobucket.com/albums/rr260/TurboThom/1997%20OB/USDM%20Retrofit/Projectors-mounted_zpse2e5c750.jpg

 

^You would have your shrouds mounted at this point. I didn't. Wanna fight about it?!

 

Seal those sexy sons of seabiscuits back up

Run your solenoid wires through the hole in the bottom of the housing, and use the kydex sheet and epoxy or adhesive sealant to seal up the giant hole you made. All done? Wunderbar! Preheat your oven to 210°F again. While that's warming up, take your headlight sealant and put it into the channels on your lights. Bake them the same amount of time as when you split them to soften the sealant. Press the lenses back into place, put all your screws and clips and thingamajigs back on. Now go take your new lights and aim them.

 

http://i489.photobucket.com/albums/rr260/TurboThom/1997%20OB/USDM%20Retrofit/DONE_zpsf63372f3.jpg

http://i489.photobucket.com/albums/rr260/TurboThom/1997%20OB/USDM%20Retrofit/DONE-CAR-FRONT1_zps24f1fea1.jpg

http://i489.photobucket.com/albums/rr260/TurboThom/1997%20OB/USDM%20Retrofit/OUTPUT_zps48513103.jpg~original

 

As of writing this, I haven't been able to properly aim my lights since the adjustment screws are stuck... but they'll move soon enough. I'm going to pull the lights and really soak the hell out of the screws. Anyway, feel free to PM me with any questions. I didn't get many photos of the process since I zoned in on what I was doing at the time and forgot about taking photos along the way.

added to sticky, nice.

I like the tough love motivation sprinkled throughout

Literally getting a chill thinking about this, very nice Thom. I think they look better than the Japanese lights and the corners line up cleaner than I have ever seen.

With some g square eyelids and bam... done like dinner.

Badass Thom! Thanks for the DIY. Think this would work with one piece USDMs?

First off, Thanks for taking the time for this write-up.

You did a good job.

How much of a gap was left between the projector lens and the inside of the oem clear plastic.

Would a Mini D2S fit?

I'm considering getting some JDM projectors, gutting them, and installing new HID housings. Too bad that the lens in my stock assembly is prisimed. Having to buy JDM projector headlights just because there is a clear, un-prisimed portion for the light to properly shine through stinks. I like that your entire lens is perfectly clear, but I have the one piece version with the integrated turn signal. I doubt anybody makes a one piece assembly with a clear lens like yours.

Do the cops give you any hassle? I don't think they're legal.

Personally, I think this modification should be ok to do as long as it is done properly. (proper cutoff, not blinding others)

It improves ones visibility and safety.

Badass Thom! Thanks for the DIY. Think this would work with one piece USDMs?

Pretty sure the flutes in the 1 piece lens would absolutely destroy the beam pattern.

 

How much of a gap was left between the projector lens and the inside of the oem clear plastic. Would a Mini D2S fit? I'm considering getting some JDM projectors, gutting them, and installing new HID housings.

Around 3/4" gap just eyeballing it. Maybe an inch. You could probably make the Mini D2S fit, I don't have the dimensions for the D2S version though. If you're doing a retrofit in the JDM projector housings, I would use FX-R projectors. There's a few people running around with that setup.

 

They're not legal at all. I'm ordering some 4300k bulbs tonight, better output and they will draw less attention. I have a straight pipe cat back and a borla header, don't need these ricey 6000k bulbs drawing any more attention to my car hah.

The D2S look like a powerful option and they're only a little bit more.

Here is a link to a HID dimensions chart.

http://www.theretrofitsource.com/pdf/trs_tech/Morimoto_Projector_Mounting_Dimensions.pdf

The D2S opens up OEM bulbs like philips and osram, but the low beam pattern isn't as good as the H1 version. The height of the D2S projector is an issue as well.

I wound up going with Bi Xenon FX-R 3.0. They are the same projector housings from an Infinity FX-45. I got them from the Retrofit Source. Here is a link to my install.

http://legacygt.com/forums/showthread.php/bi-xenon-fx-r-3-0-projector-retrofit-96-subaru-212705.html

YOU'RE in WISCO! How much do I need to pay you to make me a set??

Totally doing this in my 98 legacy soon. going to harry's to find some lights that I can tear apart. Probably getting 2 sets lol

Where are people finding the 2 piece headlights? They're off a 97 legacy as well?

 

Are they a drop in replacement for people like me with 1 pieces?

ebay mostly, but any supplier, really. i have a 95 and put the 2 piece headlights on it, the bolt spots already existed, just have to get the inserts to bolt them in correctly

I got my 2 pieces from amazon. Depo headlights. the parking lights/side markers I found on ebay.

ebay mostly, but any supplier, really. i have a 95 and put the 2 piece headlights on it, the bolt spots already existed, just have to get the inserts to bolt them in correctly

 

What do you mean get the inserts?

 

I'm hoping to pickup the 2 piece lights for cheap, brand new they're about $300 CAD for the set, and that's even before buying the projectors themselves.

The inserts are the plastic pieces that hold the corner indicator in place.

ya,the holes in the body are for the square inserts that you screw the bolts into. you dont directly thread the bolts into the metal of the body for the lights.

I got my 2 pieces from amazon. Depo headlights. the parking lights/side markers I found on ebay.

 

Thanks guys,

 

Trying to get the 2 piece headlights for cheap, as I want to do this on as much of a budget as possible.

 

The projectors are about $390 with tax and everything shipped. Would like to keep this under $500 (CAD) tops but this may not happen unless I find some headlights at a wrecker or something.

Headlights acquired, and fully polished. Projector kit should drop next Tuesday -- picked up the Acme Super H1 kit -- couldn't afford the moris, from TRS.

 

 

 

Thank you to the OP for this thread, and how to polish headlamps.

Headlights acquired, and fully polished. Projector kit should drop next Tuesday -- picked up the Acme Super H1 kit -- couldn't afford the moris, from TRS.

 

Thank you to the OP for this thread, and how to polish headlamps.

 

I wait till they have sales. they usually do crazy like 30-40% off during Holidays

 

Acmes are still decent! good luck man, it is worth every penny

I wait till they have sales. they usually do crazy like 30-40% off during Holidays

 

Acmes are still decent! good luck man, it is worth every penny

 

Wow really?

 

Good to know, i'll look out for those maybe i'll upgrade then.

 

Opened up the lights tonight - projectors should drop tomorrow.

 

Nice work!

 

it may be more like 25-30% though. still that's $60 off of $300 projector set.