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  #1  
Old 06-12-2017, 09:12 PM
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Default HID's for Blackie!

Well, Blackie is my truck. I name my vehicles. I do not know why I do that, but always have ever since my very first car.

At any rate, it is time to upgrade the headlamps from the dim, worthless halogen reflector lamps to HID. My other two vehicles have it from the factory, so time to mod Blackie and see again when I drive my truck at night.

So, I ordered two stock OEM headlight housings to do the mod with so I can continue to drive the truck and not have to hurry this project through.

I also purchase two Morimoto Mini H1 7.0 Bi-Xenon Projector housings and shrouds. Not yet decided on which ballast kit with ignitors and HID lamps to buy. Most likely Morimoto, but may go with Philips.

This can be somewhat involved project as aiming the projectors precisely can be tricky and time consuming. Given the fact I have never done this before, this could take a while. Everything has to be just so, as I am not going to be one of those asswipes who drives around at night blinding everybody. The cutoffs need to be right as well as the left and right aiming.

First thing is waiting for this heat wave to subside a bit, to heat these housings in the oven to soften the butyl, so I can take them apart and see what I am up against getting these projectors to fit.

Stay tuned.

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Old 06-12-2017, 09:39 PM
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Default Re: HID's for Blackie!

Interested to follow this. Keep us informed. With lots of photos.
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Old 06-12-2017, 09:56 PM
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Default Re: HID's for Blackie!

Quote:
Originally Posted by Melensdad View Post
Interested to follow this. Keep us informed. With lots of photos.
I plan to and I will.
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Old 06-12-2017, 10:21 PM
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Default Re: HID's for Blackie!

I've decided to build my own relay harness. That way I will know what all the components are.

#16 awg wire for the control circuits and #14 AWG for the Ballast / Ignitor circuits.

The Relays will be Temco Industrial which use #14 AWG wire for terminals 30, 87 & 87A which is the NO and NC contacts. These are Bosch style automotive relays and excellent quality. Stock photo:

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Blackie currently uses a halogen 9007 dual filament bulb for high and low beam. I will use the 9007 socket that currently plugs into the halogen bulb to supply control power 12VDC to power the relays. The issue is, only low or high beam is energized at the same time, not both. To power the HID ballasts, I need both to be hot to keep the ballasts energized. High beam is achieved by a motorized cutoff shield inside the projector housing. In order to make this work, I designed a circuit with two diodes to make this happen. The Solenoid is what power the cutoff and creates either high or low beam. Also, notice the diodes eliminate the possibility of feedbacks going back to the multi function headlight switch. Notice how terminal 86 on the relay is energized on both high and low beam but the solenoid is energized only on high beam.


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For diodes I am using a 3A 50V barrel diode.

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Last edited by TiredRetired; 06-12-2017 at 10:46 PM.
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Old 06-12-2017, 10:35 PM
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Default Re: HID's for Blackie!

I am thinking I will go with the Acme Standard 35 Watt 5000K HID bulb from the Retrofit Source dot com. They are cheap enough at 20 bucks to have as a backup spare if I decide later I want something more OEM like Philips. Stock Photo. Still trying to decide on the ballasts and ignitors but if I go with Acme on the bulbs, I may as well go with Acme on the ballast kit. Got to think about this for a bit though as I do not want to change my mind and end up having to send stuff back as all this is internet shopping.

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Old 06-12-2017, 11:59 PM
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Default Re: HID's for Blackie!

I can do the old style headlamps that were on a car no problem, but today no way. Give me an old 65 Chevy any day.

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Old 06-13-2017, 10:45 AM
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Default Re: HID's for Blackie!

Quote:
Originally Posted by MrLiberty View Post
I can do the old style headlamps that were on a car no problem, but today no way. Give me an old 65 Chevy any day.

LOL, the attached file name of that picture says "classic-65-chevrolet-impala-ss-resto-mod"

Somebody is doing some modernizing to that old girl. Those Cragar S/S wheels are the best looking wheels ever. Old School Cool, IMHO.
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  #8  
Old 06-13-2017, 12:20 PM
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Default Re: HID's for Blackie!

Up early this morning so I decided to fire up the oven and bake a housing. 250 degrees F for 25 minutes and I got the clear cover off the housing. It barely softened up the butyl rubber sealant enough but I got it. Next housing I will up the temp a bit.

As expected, the projector does not fit inside the housing. It looks good in the picture, but the glass lens of the projector hits the clear cover on the inside. No biggie, I expected that as a ruler does not lie. The next tool in this project will be a dremel with 1 1/2 cutting wheels to modify the back of the housing.

I have a battle plan moving forward, but lack the parts to do it, so I shall remove the other clear cover and clean up the old butyl.

Stay tuned.

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Old 06-13-2017, 01:44 PM
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Default Re: HID's for Blackie!

Things just got a bit easier. Rummaging through all the parts that came with the projectors for different application, I found a washer with a tab on it at the 12 O'clock position and another tab that goes into a key way on the shaft. Nice, real nice. Using this washer temporarily and lining up the tab to the notch on the housing this will give me almost perfect alignment to drill the holes for the 8-32 mounting bolts. That needs to be done before I dremel the back of the housing to move the projector back approx. 15mm or 5/8" to clear the front lens.

Stay tuned.

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Old 06-13-2017, 09:33 PM
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Default Re: HID's for Blackie!

When I drive my commuter I hate HIDs in trucks - they are too bright for on coming traffic.

I have an led light bar and fog lights in my truck - I can light up the night with everything turned on.
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Old 06-13-2017, 10:23 PM
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Default Re: HID's for Blackie!

Quote:
Originally Posted by PBinWA View Post
When I drive my commuter I hate HIDs in trucks - they are too bright for on coming traffic.

I have an led light bar and fog lights in my truck - I can light up the night with everything turned on.
Some do not bother to install HID lights in projector housings, preferring to go the cheap route and mount them in reflector housings. This is against the law and dangerous.

Others will use the projector housings but fail to aim the lights properly either through ignorance or indifference. Use of cheap Chinese ebay crap does not help the situation.

The projectors need to be aligned according to DOT specifications to keep the internal cutoff below the line of sight of oncoming traffic.

The X & Y axis need to be precisely aimed not only to maximize road illumination but to eliminate glare.

My installation will be done right and be better then OEM. Stay tuned.
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  #12  
Old 06-14-2017, 10:40 PM
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Default Re: HID's for Blackie!

Grabbed a little spare time this evening and cut out one light housing and drilled the holes for the 8-32 mounting bolts. The cover fits now, but I still need to fine tune it a bit. The holes need to be elongated a bit for rotational adjustment and after a test fit tomorrow on my truck I think I will recess the projector another 1/4 - 3/8.

You may have noticed why 3 mounting bolts instead of 4? That's because 3 bolts makes adjustment for the x / y axis much easier then if I had done 4. Easier to fine tune and make the slight adjustment. The bottom bolt for x axis or elevation and the left bolt for the y axis or left & right. The right bolt is along for the ride to pivot on and stabilize the mounting. You may have noticed that all car headlamps use 3 points for adjustment so I cannot take credit for this revelation.

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Old 06-16-2017, 03:51 PM
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Default Re: HID's for Blackie!

OK, the building portion of this projector retrofit is done. Of course the lens is not sealed, pending further alignment once mounted on the truck.

I plasti dipped one shroud black to see how it looks versus leaving it chrome. I have decided not to black out the entire housing as I originally intended. The ones I have seen on the internet I do not like as much as I thought I would. The end product will be primed with adhesion promoter and rattle canned with Fusion Black Satin.

I like how the black shroud reflects black back on the housing bowl giving it a black chrome look. A test fit on the truck looked really good.

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