Projector Retrofit: a little project

[KLAB]

...ONNN THE S^TURN!


I got these low beam projectors off a Nissan at the body shop I used to work at. Broken projector headlight assembly parts in trash pile = free projector retrofit parts . So after years of accumulating this stuff, ballasts, bulbs, and different projectors, and being SICK of stupid bright ass glaring HID's in factory reflector housings, I realized that I can try my first retro fit on this car. So I did... accidentally. Bored one day at home I decided to take my headlights out and paint around the reflectors black to have black housing headlights. It looked nice, but when I peeled the masking tape off the chrome reflector after, it peeled some of the chrome off with it >.< so looking at my projectors and ruined headlights I figured why not give it a shot. Took out the dremel and air grinder and went for it. Just takes patience opening up the hole in the back to get it to fit in, and sanding/grinding down the top and bottom sides of both the projector housing and the headlight housing to fit it in (very tight fit with the narrowness). Then I realized once it was in there I was going to need to trim the bezel it came in the headlight with because of the glaring light coming from the sides, and thats where I'm at now trying to get the bezel to work well... Then it's epoxy it in, paint it up, seal it up and wire it up and thats it! Projectors in my S^TURN for free

The donor parts:


Heres one of the low beam projectors, I know its not the best quality out there but its pretty decent and the best choice out of all my projectors for this project.


Ruined reflector headlights



Starting to cut:


Make shroud out of this?


Yup, set aside for later:


Was too busy grinding everything didn't take progress pics, that and its pretty straightforward and easy, just keep grinding till its in there. But here it is finally able to fit in:



Then after today working on the shroud:





It looks decent, and blocks the glaring light much better, but idkmaybe I should still try to make a metal shield? top and bottom if fine since the tight fit, but the sides aren't entirely blocked:




and got some pics of how its mounted and the opening:




andddd heres the electronics for it. Gonna be fun trying to seal these up good and waterproof them since these were made to be inside the sealed headlight from factory:


I think its going pretty well for my first attempt at a projector retrofit, and a kind of difficult seeming headlight assembly to do one in. But I think its going well and will have supreme lighting throughout the winter in my beater saturn DD for free, just cost a little time, and gaining experience for when I most likely do another retrofit in the future on something else.

Basically all thats left is to finalize the shrouds, paint them black or leave them chrome? ... , wire the ballasts in and everything try to seal the electricals and make water tight, and bolt the headlights and aim them before epoxying them in. Then seal them up good and of course gotta wetsand and buff the hazed lenses.
Hope it keeps going as well as it is. After this its the 95 Z28's turn. Got blazer style small Nissan projectors for fogs and bi-xenon Nissan projectors for headlights! Already brainstorming.