HID for less than $400 Part 2
 

So last fall I had assembled these:
http://forums.pelicanparts.com/uploa...1303953881.jpg
Which looked OK, but the lighting pattern was really poor. The light provided was better than the H4s, but not what I would call acceptable. Over the winter the car has gone nowhere, so I didn't even get a chance to blind any other drivers ;-) Anyway, there were several other HID builds I followed and was impressed with the results. There are here:

http://forums.pelicanparts.com/porsche-911-technical-forum/579131-my-hid-projector-build-up.html
http://forums.pelicanparts.com/porsche-911-technical-forum/604282-got-lights-new-custom-hid-headlights-arrived.html
http://forums.pelicanparts.com/porsche-911-technical-forum/582124-hid-build.html

Great work everyone I think we have quite a few options on how to retrofit HIDs in our cars. So after studying those builds I was going to do the same with a set of bi-xenon HIDs. After searching "the retrofit source" I found the Morimoto Mini H4 drop in headlights. You can get them here: Bi-xenon: Morimoto Mini (D2S) - HID Projectors from The Retrofit Source Inc

The great thing is they are only 5 inches long and from base to top only 4 inches. Not to mention they drop right into an existing H4 socket. See where this is going yet? So I ordered them with a set of GTI shrouds (there are other choices).

http://forums.pelicanparts.com/uploa...1303954238.jpg

Then I grabbed my old H4 buckets and disassembled them. You need to take them apart and remove the old internal shield. Like this:

http://forums.pelicanparts.com/uploa...1303954354.jpg
http://forums.pelicanparts.com/uploa...1303954370.jpg
http://forums.pelicanparts.com/uploa...1303954384.jpg

Next remove all the fasteners from the HIDs, feed the shutter control wires through the city light hole and then fasten in the HID. Remember to put back all the gaskets where they were originally.


http://forums.pelicanparts.com/uploa...1303954483.jpg
http://forums.pelicanparts.com/uploa...1303954496.jpg
http://forums.pelicanparts.com/uploa...1303954507.jpg

Once the HID is secure just reassemble the H4 bucket with the clear lens. No cutting, no painting, no sealer and at any time you can go back to original. :-)



http://forums.pelicanparts.com/uploa...1303954723.jpg
http://forums.pelicanparts.com/uploa...1303954737.jpg

Last I need to order ballasts and install them. Aiming should be exactly like stock and provide a perfect OE cutoff and pattern. Give me a week and I will post pictures of that.

Kevin

Couple more pics:

http://forums.pelicanparts.com/uploa...1303954697.jpg
http://forums.pelicanparts.com/uploa...1303955164.jpg

Looks great Kevin, please assemble a list of all parts used and pricing for the rest of us when done!

So far if you already have H4 assemblies you would just need the following:
2x VW beetle/356 clear H4 lenses from web $8 each
1x Morimoto Mini D2S H4 kit with shrouds, ballasts and relays from TRS for $330
Total cost so far
$346

As I look at the pictures and think about this I am going to paint the H4 buckets with some fresh silver, but if your buckets are nice and clean you probably don't need to do this. I also just ordered my ballasts and bulbs with a relay kit. Should have it early next week and I can do the install and testing.

Looks great. I wonder if there are some options for the later style I have in the 88 Carrera.

I wish those Morimotos were available a couple of years ago when I did my HID conversion. I fabbed it up in the same basic way with Audi bi zenon units. These look way slicker. less modding.

Tyler, I think you actually may be on to something. I was looking at the sealed H5 unit on the Carrera and it looks familiar. I suspect that may be the bucket Singer used on their HID conversion or at least what they used to make it. I bet if you remove the glass (heat it and separate it), mount a projector in the bucket, and then combine it with the H4 outer ring and glass it would look very similar to the Singer HID. If someone has one laying around they could take some measurements on I could tell you if it is possible.

I took the assemblies apart today and painted the buckets with a bright silver. I have to say I am really pleased with how they turned out. For the simplicity and cost this has to be the easiest solution.

I should have the ballasts and bulbs tomorrow.

http://forums.pelicanparts.com/uploa...1304113536.jpg
http://forums.pelicanparts.com/uploa...1304113574.jpghttp://forums.pelicanparts.com/uploa...1304113685.jpg

Looks really good!!

Here are the last pics. I got them all wired up and working today. I am really happy with how they look and the pattern. I just need to set the height of them in the driveway sometime this week. Hope this helps someone out :-)

Low Beams
http://forums.pelicanparts.com/uploa...1304288261.jpg

High Beams
http://forums.pelicanparts.com/uploa...1304288272.jpg

Finished product
http://forums.pelicanparts.com/uploa...1304288281.jpg

So were these done with Porsche H4's or the VW H4 shells and Porsche trim rings?

Those were the porshe h4 buckets, but you could do the same with the vw buckets too. For the vw h4 assmbly you would just have to take the glass off of the internal lamp and just use the refector. Probably would look the same.

what are the ballasts and bulbs you are talking about? what about the relays?

Neat solution! Just don't paint eyelashes on a la Miura ;)

Here is the complete kit with everything minus the clear vw lenses.

Bi-xenon Morimoto Mini Stage III Kit (D2S) - Complete Retrofit Kits from The Retrofit Source Inc

more silly questions, what are the ballasts? was the installation of the relays and the ballasts straight forward? I read in GSsmiths thread that the VW clear lenses were a little loose in the H4 shells. did you find that as well?
last question, is that kit the full set bar the clear lenses? that's a great deal! less than $300.00

Did mine for under $200.00 my buckets already set up for h3 bulbs so it was just plug and play ballasts mounted inside trunk.
No problems with the police yet but in my jurisdiction it is actually illegal to have HID's that are not self leveling.

Paul, the ballasts are the circuitry that run the HID bulbs. If you follow the link I posted above you can see the picture of them. With the relay kit from TRC everything is plug and play. Everything you need is there. You just have to route all the cables and secure everything where you want it. The only modification to the car is the back of the headlight bucket needs to be cut out to clear the back of the bulb connector. I am still thinking through that one to come up with a nice clean solution for it. Follow one of the links of the other HID builds to see pictures of where the ballasts were mounted.

As for the lenses mine were tight and fit perfect. If they are loose they may need a new gasket.

I checked out the link on TRC for the retrofit kit but there are quite a few selections for each part of the kit. Which items did you pick from the list? The angel eyes look like they could be useful as running lights. Did you consider using them?

I picked the GTI-R shrouds, 5000K bulbs, and you need the H4/9003 relay kit. I didn't do the angel eyes because I thought it wouldn't look right on the car. The morimoto long D2S ballast cords would be nice, but they were out of stock on them. I used the standard length ones.

thanks for all the info kevin!

Awesome. Thanks so much! This thread will help a lot of folks.

J

Are the VW clear glass lenses dome shaped ? They dont have the 911 euro shape its hard to tell from the photos, I dont think I have ever seen clear ones are they early 6v Bug glass? Its good that the conversion is available in RHD too.
As the wires for these lamps exit the assy through the park lamp receptical does the HID have its own park light or is the original remounted or not used ?I think they look really good and the whole conversion is well done.:)

Those look pretty good I just saw this thread and that is the closest match to the singer lights I think I have seen, Good Job!

Here is another pic with the headlights in. I was going for the look of the Singer and this is pretty close.

http://forums.pelicanparts.com/uploa...1330713723.jpg

Mike, how did you do it for under $200? Can you list some detail with pricing?
Thanks.

Is there any way to do this without cutting the headlight bucket? How much room is there between the projector lens and the clear headlight lens? Maybe a custom backing plate?

Thanks,

BernieP

Kevin did you have to cut your headlight buckets? I would have thought you didn't because you mounted yours using the H-4 socket. I do know the D2s lights do stick out the back of the projector a ways. This would have been a good way to go for me but I was looking for more of the later stock look with the stacked lights like Lateapex did.

kevin,

looks great I would like to do this with my h5's on my 964 though not sure if it could happen . you still in Racine that i could check it out sometime in person?

HID's on a 964...

Let there be light: 964 HID project - Page 5 - Rennlist Discussion Forums

Unfortunately I did have to cut the back of the bucket. If the wiring was a bit more flexible I think it could be squeezed in without cutting. This summer I may force Jay to do this to his car so we will try to work out that last little bug. If we can figure out how to not cut the bucket and get the same look I will post up the details.

Ben,

I am still in Racine, so any time you want to come out let me know. I would love to see your 964 too.

Kevin

I am contemplating when I get the fiberglass fenders I will probably fab up a box over the hole to seal up the buckets but I really don't think cutting the buckets are such a bad deal I have no indication of debris getting into the bucket from the rubber flap I made up. The D2S plug only lacked about a half inch of clearing the buckets on my installation and I just figured that was because I set the lights up high in the housing. I think mine would have cleared if it was centered like yours are.

I am not sure what H-5's look like. Don't they attach to the same mounts that sugar scoops mount to? Post some pics you might be able to fab up a plate like I did to mount in the bulb bracket and depending on clearance it might not need the bucket cut

Ben if you can bring your car over I have a theory that the H5s may work with little to no modification at all. Just a HID assembly bolted into the back of the bucket and a clear lens should work. However this is just a theory. ;-)

if u guys need a picture of the back of H5 i got one ;)

Hi Kevin,

When mounting the Mini's this way, did the shroud sit flush with the reflector? Is there any gap noticeable once the headlight is mounted?

Thanks,
Adam

I am puzzled by what the silver shield looking thing is around the projector shroud. Looks like it covers the top 5/6 of the projector but is open on the bottom.

The descriptions of the pictures and the 'parts needed' descriptions seem to mention nothing about this.

Thanks in advance.

I love the look of this but the thing that concerns me is the loss of the sidelight (city light I think you call it)

I need those for our annual "safety" check

I did the conversion and kept the citylights intact as well as modified the headlight assembly so I did not cut the headlight buckets.

Any chance of some pics of how you've done it or the result?
Did you use the morimoto d2s?