Attention: TDR Forum Junkies Hi All,
First, let me say this is going to be a long post with many pictures. I bought my truck new and was initially impressed with the headlights (especially when compared to my prior '89 and '95 Rams. But as time went on I had several "close calls" at night due to the lack of distance in our beams. Recently this became more prevalent when my wife and I moved further out from the city. So I began to look at the possibility of upgrading the lights. We've seen impressive setups here on the TDR of off road lights and even another HID setup. So after months of reading, researching, and planning, I decided to do a custom Bi-Xenon HID retrofit.
I've seen the "kits" and the blinding glare that they produce--so this was quickly taken off the table. I've also seen some retrofits that required extra switches and what not--I wanted a factory look. I didn't want to lose any functionality, so I had to have both High and Low beams. Lastly, I wanted to do this modification without hacking up the existing factory harnesses.
Now, what kind of projectors? I started researching to find out what exactly is the best projector? So, I went to HID Retrofit Parts Projectors Ballasts D2S Bulbs to see what others use. Many prefer the Honda S2000 projector, but it is low beam only. Others like the Lexus LS430, but it too is low beam only. Very few people use the LS460--some even say it's no good--but this appears to be without significant merit. Next, I found out that the Lexus LS460 is a low beam only here in the U. S. , but in China and Taiwan, the LS460 comes with a Bi-Xenon (high and low beam) Projector! Now, how do I get a set of LS460 projectors from overseas? Well, I found a supplier in China who sells projectors from salvage vehicles and luckily he had a set. REMEMBER to make sure you buy a LEFT and RIGHT side projector--very few types are interchangable.
View attachment 72965
Additionally, here in the U. S. we are Left hand drive, so I needed a set of Left hand drive projectors--China and Taiwan are. THIS IS IMPORTANT because the projector beams have a "step down" in the beam pattern cut-off to prevent the blinding of oncoming drivers (I have a picture of it later in the post).
Now, although the projectors are key, you got to have bulbs! So, I found out what type bulbs Lexus is supplying in the new LS460s and ordered a set. Manufacturers are using new Mercury free D4S bulbs and ballasts--so I got a set of new Lexus (Phillips) bulbs and Lexus Ballasts. These new "environmentally friendly" mercury free bulbs will help to offset my "Carbon Foot Print" from that nasty habit my Cummins has of smoking the unsuspecting Hemi---HA!
Projectors sourced from auto-electronic.net
Next is wiring, I ordered everything from parts-express.com, mouser.com, and suvlights.com.
I used parts-express for the relays, pigtails, diodes, and fuses.
2-relays (Tyco 20/30A SPDT)
2-pigtails for relay (5 pin relay socket)
2-diodes (1N4007 1A 1000V diode)
2-fuse holders (in-line 10 AWG--30A rated)
I used Mouser.com for the resistors and thermal potting compound.
4-resistors (ARCOL 4. 7 Ohm)
1-potting compound (MG Chemicals Thermally Conductive, 450mL)
I used suvlights.com for the 9007 male socket pigtails
I used a couple of spools (red and black) of 14 AWG wire from Tractor Supply for the main wire runs.
Now, after all the parts were amassed, time to take out the lights and get them in the oven---yes the oven. I set the oven at 290 degrees and put the whole headlight assembly inside for about 8 minutes. BE SURE to put something down on the racks so that the metal grid doesn't melt your plastic housing--I used a couple of cedar blocks. The oven is necessary to heat the lights and glue up to be able to remove the front lens.
Inside the oven (Do this when wife is not around).
View attachment 72966
You may have to repeat a few times (a couple minutes each time) to keep the light warm enough for the lens glue to peel apart.
View attachment 72967
Once opened, you have access to the reflector bowl. Repeat this for the other side.
View attachment 72968
Ok, next post will have parts/wiring pictures. I'll indicate when the final post is up.
(Hope the pictures work--if not, I'll fix)
First, let me say this is going to be a long post with many pictures. I bought my truck new and was initially impressed with the headlights (especially when compared to my prior '89 and '95 Rams. But as time went on I had several "close calls" at night due to the lack of distance in our beams. Recently this became more prevalent when my wife and I moved further out from the city. So I began to look at the possibility of upgrading the lights. We've seen impressive setups here on the TDR of off road lights and even another HID setup. So after months of reading, researching, and planning, I decided to do a custom Bi-Xenon HID retrofit.
I've seen the "kits" and the blinding glare that they produce--so this was quickly taken off the table. I've also seen some retrofits that required extra switches and what not--I wanted a factory look. I didn't want to lose any functionality, so I had to have both High and Low beams. Lastly, I wanted to do this modification without hacking up the existing factory harnesses.
Now, what kind of projectors? I started researching to find out what exactly is the best projector? So, I went to HID Retrofit Parts Projectors Ballasts D2S Bulbs to see what others use. Many prefer the Honda S2000 projector, but it is low beam only. Others like the Lexus LS430, but it too is low beam only. Very few people use the LS460--some even say it's no good--but this appears to be without significant merit. Next, I found out that the Lexus LS460 is a low beam only here in the U. S. , but in China and Taiwan, the LS460 comes with a Bi-Xenon (high and low beam) Projector! Now, how do I get a set of LS460 projectors from overseas? Well, I found a supplier in China who sells projectors from salvage vehicles and luckily he had a set. REMEMBER to make sure you buy a LEFT and RIGHT side projector--very few types are interchangable.
View attachment 72965
Additionally, here in the U. S. we are Left hand drive, so I needed a set of Left hand drive projectors--China and Taiwan are. THIS IS IMPORTANT because the projector beams have a "step down" in the beam pattern cut-off to prevent the blinding of oncoming drivers (I have a picture of it later in the post).
Now, although the projectors are key, you got to have bulbs! So, I found out what type bulbs Lexus is supplying in the new LS460s and ordered a set. Manufacturers are using new Mercury free D4S bulbs and ballasts--so I got a set of new Lexus (Phillips) bulbs and Lexus Ballasts. These new "environmentally friendly" mercury free bulbs will help to offset my "Carbon Foot Print" from that nasty habit my Cummins has of smoking the unsuspecting Hemi---HA!
Projectors sourced from auto-electronic.net
Next is wiring, I ordered everything from parts-express.com, mouser.com, and suvlights.com.
I used parts-express for the relays, pigtails, diodes, and fuses.
2-relays (Tyco 20/30A SPDT)
2-pigtails for relay (5 pin relay socket)
2-diodes (1N4007 1A 1000V diode)
2-fuse holders (in-line 10 AWG--30A rated)
I used Mouser.com for the resistors and thermal potting compound.
4-resistors (ARCOL 4. 7 Ohm)
1-potting compound (MG Chemicals Thermally Conductive, 450mL)
I used suvlights.com for the 9007 male socket pigtails
I used a couple of spools (red and black) of 14 AWG wire from Tractor Supply for the main wire runs.
Now, after all the parts were amassed, time to take out the lights and get them in the oven---yes the oven. I set the oven at 290 degrees and put the whole headlight assembly inside for about 8 minutes. BE SURE to put something down on the racks so that the metal grid doesn't melt your plastic housing--I used a couple of cedar blocks. The oven is necessary to heat the lights and glue up to be able to remove the front lens.
Inside the oven (Do this when wife is not around).
View attachment 72966
You may have to repeat a few times (a couple minutes each time) to keep the light warm enough for the lens glue to peel apart.
View attachment 72967
Once opened, you have access to the reflector bowl. Repeat this for the other side.
View attachment 72968
Ok, next post will have parts/wiring pictures. I'll indicate when the final post is up.
(Hope the pictures work--if not, I'll fix)
