Has anyone ever done this to the cheap aftermarket projector style headlights that are available for our trucks?

I've never had personal experience with these headlights, but I've heard more than once that the light output is terrible... So I had thought about getting some, opening them up, and installing some REAL HID bi-xenon projectors in them in place of whatever crap is in them new.








I've done several projector retrofits with great results. I did a set of aftermarket clear headlights for my Blazer some time back, and the lenses have started fogging up and I've been fighting moisture inside one of them, and I'm just tired of dealing with them and am ready to just replace them lol. It was a real chore to get them to fit inside of the basic clear lens aftermarket lights; lots of cutting and even clearance the radiator support because of how far back the projector had to sit into the light... Just wondering if these lights that already have projectors in them would be any easier to convert over.

Thanks!

 

I had a set of the spyder “projector” headlights for a short time. They come with 55w H1 halogen bulbs. When I got mine, I immediately installed 35w HID, everything was wired right, ballasts were powered off relays and all connections soldered.
Although this set up provided a nice crisp cut off line, overall light output was less than spectacular. In fact, in my opinion it was much less than the 130w halogens I had in my stock lenses (although “whiter”).

When I investigated a little further as to the cause, I found that the overall diameter of the spyder projector is much smaller than the “real” projectors like the morimotos. I’m guessing the smaller diameter, plus poor reflector and optics are the reason for the lousy output.

For a couple other reasons in the end, I went back to a modified version of the factory headlights.

 

Yeah judging by just pictures the lens definitely look smaller than the 2.5" lenses in the Morimoto Mini H1 7.0's that are in these lights I built for the Blazer, or the cheap clone Mini H1's I have a dozen of in the garage left over from when I was doing some retrofits for friends lol. I also have some LED projectors out of a Prius that I've been wanting to try on something, I'm not sure on how big those are exactly, they're buried in a box in the garage somewhere...

I have no issues dremeling out the opening for the lens if needed, but I would cross that bridge when I get there if it came to that.

I've been spoiled by the light output of good projectors now, so there's definitely no going back to stock reflectors or sub-par projectors lol

 

Yeah I can’t blame you, IMO nothing beats a good projector. Luckily I’ve got them in both of my “good” cars, so the dd makes do with a new set of factory reflectors with some higher output mods.

I considered installing a set of good projectors, and read a ton of info on the subject. I even went so far as to attempt to remove the lenses from the spyder lights with the oven trick, but found that the sealer they use is more like a glue and doesn’t like to loosen up with heat.

My 4 inch diameter cold air intake tube is now directly behind the driver side headlight. I felt that installing a projector that went back into that space would be counter productive, so I never went any further with the idea and concentrated more on making the stock lights better.

Just this past week I finished with a 2 year frame off restoration of the truck, so now that it’s finished perhaps I’ll revisit the headlight projector idea.

 

Well last night I went ahead and ordered a set of the headlights, so I'm diving into this and we'll see how it goes

 

Good luck with it. You’ve got the experience so I’m sure putting it together won’t be a problem for you.

As of now, I’m running S-V.4 led high beams and (I know the SJW light police will be cringing) 55w hid 6k low beams.

I aimed them as per spec against a wall at night, and the hot spot on the driver side is down and to the right as it should be. Passenger side is pretty straight ahead and down, so glare is kept to a minimum.

My truck is lowered, so aiming the lights properly is tricky, but by trial and error I can usually get them just right.

On a side note, I’ve wired a diode into the ground circuit, so quad-4 beams light things up quite nicely when appropriate 😎

 

Thanks. Hoping it goes to plan lol.

The current setup is the retrofitted clear aftermarkets, Morimoto Mini H1 7.0's, but running cheap eBay 55w 6000k bulbs in them with some cheap digital ballasts. They output is amazing, and despite using cheaper bulbs and ballasts, I've never had any issues with them. Also using cheap LED bulbs in the high beam spots. They're not really bright by themselves for high beams, but luckily the bixenon feature of the Mini H1's has made that a non issue lol.

These retros came out looking and working great. I wanted something that didn't look ricey looking, and the end result was an almost OEM looking projector headlight. I just wish they didn't have the constant moisture issue... The back housing on one of them cracked and split during the lens separation. I tried to seal it the best I could, but I don't know if the moisture is getting in there, around the lens, where I sealed the back of the projector bowl to the back of the housing, no idea... But the light assemblies themselves are older, the lens is in rough shape now, so I just want to do away with them and start over...









I'm also using Blazer brand projector fog lights I pulled off a Corvette in the junk yard, threw some 55w 6000k HID's in them too and they're stupid bright for they're size, and have a great cutoff. I can actually drive at night with JUST the fog lights on as low beams lol.

 

I want so bad for non Chinesium garbage projectors for the Blazer. I have extra bright sylvana bulbs right now and they kind of suck.

 

Well hopefully it's a somewhat straight forward projector swap. I'll take photos and document the process!

 

If it turns out well, any chance of you doing a commission to make another set?