DIY: Retrofit in EK with Ebay headlights
 

I never really liked the stock headlights so i picked up a pair of ebay headlights and the output was medicore at best but i just lived with it for a very long time. But today that all changes! =D

I've never tried it but i was inspired by ahmed_17's thread about his retrofitting found here

so i figured i'd give it a go myself as well

The Ebay headlights are angel eyes with the hi and low beam split so i went for the tsx projectors.

my tools and parts list consisted of:
EBay headlights
TSX clear lens projectors
D2S hid kit
JB weld
saw/knife
drill
lego (will be explained)
silicone
rubbing alcohol and cloth
electrical tape
screwdrivers and socket and ratchet

start off by taking the headlights off the car
http://img24.imageshack.us/img24/372...0907201852.jpg

preheat the oven at 350 degrees F then turn off the oven and place your headlights into the oven for 10 minutes. take it out and use a flathead screw driver to help you pry the headlight apart, it should come out fairly easily but if not then just repeat until success.
http://img24.imageshack.us/img24/720...0907201853.jpg

the stock projectors from the headlights came with separate brackets for the pitch and yaw so i just measured the placement of the lens with respect to the adjustment brackets and then JB welded the brackets onto my tsx projectors with the same measurements.
http://img24.imageshack.us/img24/548...0907201931.jpg
http://img199.imageshack.us/img199/6...0907201854.jpg

If you don't have someone to help you, the measurements while holding the brackets in place can be tricky, especially when you're tring to JB weld it in place at well. To solve this dilemma, i used lego......
http://img199.imageshack.us/img199/1...0907220215.jpg
http://img22.imageshack.us/img22/343...0907220215.jpg

wait for everything to dry and cure and then mount the new projectors onto your headlight...you will have to cut out some of the back as the tsx projectors are a bit fatter...lengthwise it was almost identical but the diameter at the back was noticeably larger and would not work with an unmodified openning at the back so just cut away what's necessary for it to work. some places may be hard to cut, so just drill holes as close as possible to each other in the contour of what you want cut out and then either snap it off or punch it out.
http://img22.imageshack.us/img22/16/...0907221829.jpg
http://img24.imageshack.us/img24/652...0907221829.jpg

once you have it in place, preheat the oven again at 350 deg. F turn off the oven stick your headlights in for 10 minutes, take it out and put your headlights back together.
http://img22.imageshack.us/img22/901...0907210149.jpg

now wire up the harness for the hid's...but not the bulbs and the wire that connects to the bulbs. take those and fit it into the projectors of the headlights. you'll notice that it may stick out a bit more and it's also not going to seal back up with the original rubber cover. what i did was cut a slit through half the rubber cover so you can run the wire out and then tape up the remaining little cracks and such to seal it.
http://img20.imageshack.us/img20/866...0907222015.jpg

put your headlights back on, if you wish, you can silcone around the headlight to ensure a better seal, connect everything back up and you're ready to go!

As a reference these are what my headlights look like on my car...before and after pics look exactly the same since i only swapped out the projectors
http://img31.imageshack.us/img31/3766/img3287y.jpg

here are some pics of the end result, i only had the camera on the phone and it started raining so i didn't have much time to aim the headlights and everything
http://img22.imageshack.us/img22/488...0907230140.jpg
http://img114.imageshack.us/img114/5...0907230139.jpg
http://img114.imageshack.us/img114/9...0907230157.jpg
http://img24.imageshack.us/img24/133...0907230159.jpg
http://img20.imageshack.us/img20/373...0907230005.jpg


Oh and if you somehow end up making a mess of your clear cover on the headlights or something, maybe accidently got some glue on it somehow use rubbing alcohol to get it off

Hope you guys enjoy this =)

Very nice work, loving the use of lego, very smart idea

nice write up

great write up why didn't you swap your halo rings with CCFL ones in the mean time?

Its a nice one, I think you must got this on a very reasonable price and it looks like as a very good one also.

i like when people use their brains....nice work...and lego is never out of use...lol

nice!!...i'm gonna use the exact same thing but with MORIMOTO MINI projectors and try to fit h1 bulbs in the original ebay projectors for my DRL.