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Old 07-11-2013, 02:06 PM   #1
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Retrofitting HID Projectors into a TJ

Hey everyone. My next mod is going to be installing HID projectors into my TJ. You don't see it very often, and I didn't find much info online, so I'm making a build thread for them.

So here is the plan:
  • High-ish quality Morimoto Mini H1 bi-xenon HID projectors from The Retrofit Source plus accessories
  • Modify stock JK housings to mount the projectors

The reason I decided to go with the Morimotos and retrofit rather than ebay lights, is that the quality of the projectors far surpasses anything you'll find on ebay for $100. The light is very evenly dispersed with no hotspots or the like, and the low beam cut off is very, very sharp. I've personally seen these lights retrofitted onto my friend's Honda Civic (go ahead, laugh) and they are absolutely fantastic. His high beams are brighter than my highs, fogs, and 6" KC Daylighters combined.



So the idea is that you aim the cut off at the base of the average car's windshield or rear window. That way, you don't blind them, but can see everything. Then when you hit high beams, the cut off shield moves and you can use all of your light.





I decided to use the JK housings because you can easily cut them to modify them, they have a clear lense that won't scatter the light of the projector, they mount right up to a TJ, and still say DOT approved on the front which is fairly important being in a state that requires state inspections.

So here is what I ordered:

I also tossed in a set of amber led angel eyes to place behind my shrouds. I want to wire them as DRLs and to flash with my turn signals. This is what they'll look like:



All of my stuff came in the other day!











Updates to follow as I get some progress done.

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Old 07-11-2013, 11:15 PM   #2
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Why are you using H1 HIDs instead of H4s?

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Old 07-11-2013, 11:50 PM   #3
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Why are you using H1 HIDs instead of H4s?
There isn't an H4 projector that is decent that I could find. I feel like you really need the larger lense.
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Old 07-12-2013, 04:36 PM   #4
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Correct. An H4 projector would be far too large for the JK housing. Please keep on posting your step by step process. Looking forward to seeing the end result! If you can do a step by step, that would be awesome.
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Old 07-12-2013, 11:41 PM   #5
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Correct. An H4 projector would be far too large for the JK housing. Please keep on posting your step by step process. Looking forward to seeing the end result! If you can do a step by step, that would be awesome.
Will do! You've done a retrofit, right? This week I'll be probing the jeep for voltages and stuff to see how I want to wire my angel eyes behind the shrouds. I'd like them to be DRLs and flash with the turn signals, which I am fairly certain can be done with a few relays. So this week is planning, next weekend is the install.
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Old 07-17-2013, 11:57 PM   #6
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Hey bud, can you do me a favor when you have a sec, can you snap a pic of the bixenon actuator connector coming off the projector?
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Old 07-24-2013, 04:07 PM   #7
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Hey bud, can you do me a favor when you have a sec, can you snap a pic of the bixenon actuator connector coming off the projector?
Sorry didn't see this till now! Yeah I'll take a pic for you. Install is now moved to august 3rd. Life's been pretty busy lately.
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Old 08-02-2013, 11:20 AM   #8
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cant wait to see the build log and results! this is looking like a project that im gonna have to do. good luck
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Old 08-02-2013, 12:11 PM   #9
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Hurry up Wes, I'll let you build me a set next
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Old 08-03-2013, 08:36 PM   #10
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Hey bud, can you do me a favor when you have a sec, can you snap a pic of the bixenon actuator connector coming off the projector?
This thing?
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Old 08-05-2013, 10:57 AM   #11
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So here are some pictures of the final product. It'll take me a day or do to get the write up made. It took my 2 friends and I 10hrs to install them because cutting the JK housings was trickier than I thought it would be. Aesthetically, they're not perfect, but that's my fault and you can only notice the imperfections from up close. I've got to say though, there is something sinister looking about my shroud with the led ring behind it, I love it. But, I am super impressed with the performance thus far. We got them aimed last night and went for a drive. The low beam cutoff is razor sharp and has this cool color banding effect, and the high beam has very wide and tall coverage. I can see more on low beams than I could previously with high beams. Also, my KC Daylighters and factory fog lights are now pretty much useless. I'll be aiming the KCs way off to the side and only use the fogs during poor weather like they're intended. Anyways, onto the pics.

















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Old 08-05-2013, 11:26 AM   #12
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This thing?
See the wire in the pic (the red and black one?) I wanted to see the end of that wire, what the connector looks like.
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Old 08-05-2013, 11:37 AM   #13
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See the wire in the pic (the red and black one?) I wanted to see the end of that wire, what the connector looks like.
Ah, okay. I'll grab another picture then. The ends had spade connectors on them then my kit came with a plastic connector and weather proof bushings to put over them.
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Old 08-05-2013, 11:43 AM   #14
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Sweet! How hard is it to adjust them? It looks like the housing hides the adjustment screws. I guess when you take the trim piece out there is enough room for adjustment?
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Old 08-05-2013, 12:10 PM   #15
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Sweet! How hard is it to adjust them? It looks like the housing hides the adjustment screws. I guess when you take the trim piece out there is enough room for adjustment?
If you have a long torx screw driver there are slots in the trim ring to adjust them. But I only have torx attachments for my screw driver, so I have to take off the black bezel to aim them. Not a big deal since it's 3 screws. To aim them there are 2 adjustment screws behind the retaining ring. Very small turns make the headlight move significantly. Very easy to aim, but it helps to have a friend.
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Old 08-05-2013, 12:14 PM   #16
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Did it look like this little black one...like a weird trapezoid type?
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Old 08-05-2013, 12:15 PM   #17
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If you have a long torx screw driver there are slots in the trim ring to adjust them. But I only have torx attachments for my screw driver, so I have to take off the black bezel to aim them. Not a big deal since it's 3 screws. To aim them there are 2 adjustment screws behind the retaining ring. Very small turns make the headlight move significantly. Very easy to aim, but it helps to have a friend.
Go to Home depot and get the correct tool, it's only $4. Made my life a lot easier.
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Old 08-05-2013, 01:12 PM   #18
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Did it look like this little black one...like a weird trapezoid type?
No, the spade connector went into the plastic piece which looks like I believe an HB3/HB4 connector. Kind of an oval shape. However, that picture is what the connector for my bulbs looks like.
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Old 08-05-2013, 04:27 PM   #19
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so how much are you into this, pocketbook wise?
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Old 08-05-2013, 04:28 PM   #20
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Any pics during the process? Or maybe you coulda ell us why the lenses were more difficult to cut than you imagined?
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Old 08-05-2013, 06:41 PM   #21
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so how much are you into this, pocketbook wise?
He should be well under any aftermarket quality solution. 150 for projectors, 20 for a harness, 50 for an HID kit, and that's all she wrote.
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Old 08-05-2013, 07:27 PM   #22
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so how much are you into this, pocketbook wise?
I estimate around $350 including epoxy and such for modification, but I'll have to total it later.

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Any pics during the process? Or maybe you coulda ell us why the lenses were more difficult to cut than you imagined?
Sure thing, I'm going to make a write up with pictures tonight or tomorrow. Took about 200 pictures, most of which are garbage.

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He should be well under any aftermarket quality solution. 150 for projectors, 20 for a harness, 50 for an HID kit, and that's all she wrote.
$300 for the projectors, bulbs, shrouds, harness, and amber halos. $50 for the jk housings. A few extra dollars for the modification for things like solder and epoxy.
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Old 08-06-2013, 01:07 PM   #23
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Looks real nice. Now I'm struggling with this or the JW speakers...
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Old 08-06-2013, 01:13 PM   #24
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Looks real nice. Now I'm struggling with this or the JW speakers...
Don't struggle. These are better. The speakers are still the best in terms of LED, but they still fall short of HID. Save yourself the money, and do it right.
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Old 08-06-2013, 01:34 PM   #25
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Do you have high beams also?
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Old 08-06-2013, 02:40 PM   #26
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kudos! they look great!! cant wait to see the write up, especially the wiring of the drl's and halos. i'm about to do this to my '03 X. i did the ebay HID low rent job on my chevy truck and it was a nightmare. the install was easy as pie, but the occasional non-starts, flickering and having to try to the off-on-off-on over and over to get them to fire was frustrating to say the least. and that one was supposed to be "plug and play" with the proper harness....not so much.
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Old 08-06-2013, 02:52 PM   #27
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Do you have high beams also?
I do have high beams! The low beam cutoff shield moves out of the way thanks to a solenoid when I pull the stalk toward me for high beams. If I can find my camera I will make a video as well.

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kudos! they look great!! cant wait to see the write up, especially the wiring of the drl's and halos. i'm about to do this to my '03 X. i did the ebay HID low rent job on my chevy truck and it was a nightmare. the install was easy as pie, but the occasional non-starts, flickering and having to try to the off-on-off-on over and over to get them to fire was frustrating to say the least. and that one was supposed to be "plug and play" with the proper harness....not so much.
The DRL's unfortunately did not work out. It was either have them as turn signals and parking lights, or DRLs that shut off when I turned on my lights. Since they are amber, I opted for turn signals. I may add a single led to the housings later for a drl. I'm glad you've seen the light (pun intended) I'm regards to the ebay HID kits. Cheaper, but horrible light distribution and hardly any low beam cut off.
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Old 08-18-2013, 08:18 PM   #28
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I do have high beams! The low beam cutoff shield moves out of the way thanks to a solenoid when I pull the stalk toward me for high beams. If I can find my camera I will make a video as well.

The DRL's unfortunately did not work out. It was either have them as turn signals and parking lights, or DRLs that shut off when I turned on my lights. Since they are amber, I opted for turn signals. I may add a single led to the housings later for a drl. I'm glad you've seen the light (pun intended) I'm regards to the ebay HID kits. Cheaper, but horrible light distribution and hardly any low beam cut off.
I believe your a nova jeeper? Id definitely supply some Beers and all if you were open to helping me out on install one day. I recently got hella e codes h4s, any idea if that would be a good housing vs the jk housings? Can the amber eyes be changed to other colors such as blue?
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Old 08-18-2013, 08:23 PM   #29
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I do have high beams! The low beam cutoff shield moves out of the way thanks to a solenoid when I pull the stalk toward me for high beams. If I can find my camera I will make a video as well.



The DRL's unfortunately did not work out. It was either have them as turn signals and parking lights, or DRLs that shut off when I turned on my lights. Since they are amber, I opted for turn signals. I may add a single led to the housings later for a drl. I'm glad you've seen the light (pun intended) I'm regards to the ebay HID kits. Cheaper, but horrible light distribution and hardly any low beam cut off.
Glad you finally saw the light of HID+projectors. LEDs aren't there yet, which is why I always recommend people go this route. If a bulb burns out, you can replace it for $10 instead of throwing away a $400 headlight. The beam pattern is also far superior to anything on the market, including the DOT stamped stuff. Great job and enjoy them.

BTW, if you want a little bit more light, upgrade to 55W ballasts, you'll be even more impressed.
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Old 08-18-2013, 11:04 PM   #30
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I believe your a nova jeeper? Id definitely supply some Beers and all if you were open to helping me out on install one day. I recently got hella e codes h4s, any idea if that would be a good housing vs the jk housings? Can the amber eyes be changed to other colors such as blue?
I am! Though, I'm rarely in Nova anymore as I go to school at Virginia Tech. Help installing is definitely not out of the question though. I'll have to wait a little while before doing it again so I don't lose my sanity lol. It took me and some buddies 10hrs to install mine

You can get different colored rings, but not from the TRS site. They only have amber and white. I don't recommend blue though, you'll get a ticket pretty quick. Non-police/emergency vehicles are supposed to have blue lights on them. Just a heads up.

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Glad you finally saw the light of HID+projectors. LEDs aren't there yet, which is why I always recommend people go this route. If a bulb burns out, you can replace it for $10 instead of throwing away a $400 headlight. The beam pattern is also far superior to anything on the market, including the DOT stamped stuff. Great job and enjoy them.

BTW, if you want a little bit more light, upgrade to 55W ballasts, you'll be even more impressed.
Maybe you have me confused with someone else? I never was on board with the LEDs for headlights. The two options we have are over priced and have pretty poor performance.

My high quality bulbs are around $70 for the set, but I get what you mean. Apparently the "nicer" bulbs have the arc very precisely aligned and such. I dunno. I stick with Phillips/Ossram.

Is the increased light output really that much more? I'd have to see it before sacrificing the heat increase and ballast/bulb life and reliability before dropping the coin on a 55w set up. Definitely a possibility in the future though.

Here is a little preview of the low beam cutoff. My yard is sloped, so that's why the cutoff is angled to the left. Also, I just realized tonight that I didn't get my passenger side perfectly aimed it needs to come down a tad.


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