Projector headlight build

08arcticcat · Dec 16, 2020

After burning out my mini h1 headlights i had built for me back in 2012/13 i decided to try my hand at making my own.

I have been running 55w hid in the morimoto mini h1 for 8 years and the output was declining down to where its terrible. Finally i decided to do something about it.

I ordered a set of morimot D2S 5.0 projectors, some 4500K D2H bulbs, the wiring, and the butyl from Winnipeg HID on black friday, he has been awesome to deal with.

I researched this for weeks, watched as much youtube as i could. Joined headlight junkies on facebook, and searched back years on facebook on the groups for my trucks bodystyle.

This week off i finally decided to pull the trigger. Into the oven they went. I found 240F for 14 minutes, then 8 minutes and then 9 minutes was enough to open the headlight without enough struggle that new swear words were invented.

Cleaning the permaseal out of the grooves was a huge PITA!

I bought a dremel to increase the opening size in order to fit the d2s threaded shaft. The dremel came in handy for butchering the shround down to a size where it would fit.

08arcticcat · Dec 16, 2020

Low beams

High beams

Not gonna lie, i took my time, and i dont work overly hard, just a consistend pace. I took lots of small cuts on the shrouds instead of big chunks. I definitely have a few flaws i notice in my work, i broke a tab off the back of the headlight assembly.
I have probably 20+ hours and im not quite done, gotta clean the finger prints off the lenses and seal em back up.

Summitric · Dec 16, 2020

were you headlites already projector style? I have a 2016 Ram Longhorn 1500 with projector, but brighter 9005 bulbs, and gonna put some LED's in them... just gotta find the proper ones to fit the housing(the fans on the back of the LED's won't fit the housings) so only able to do the fog lites for now

08arcticcat · Dec 16, 2020

No, these headlights were the factory quads. When i got my old lights built the guy used some quads and put h1's into.

This set is my factory quads that have been in boxes since 2013 and im putting the d2s projectors into

firstdoo · Dec 16, 2020

That's a cool little project. But the picture that stuck out the most for me was the headlight in the oven. That is the cleanest oven I have EVER seen. Either you have an amazing wife, or you've never cooked a meal in it.

Frankenytro · Dec 16, 2020

looks as clean as every oven I have ever seen in a holiday trailer lol. Never once have I seen one lit.

firstdoo said:
That's a cool little project. But the picture that stuck out the most for me was the headlight in the oven. That is the cleanest oven I have EVER seen. Either you have an amazing wife, or you've never cooked a meal in it.

doorfx · Dec 16, 2020

Lol we have cooked roasts, chicken , fish in our oven. As soon as we park I light the oven pilot light.

busted2x · Dec 16, 2020

Summitric said:
were you headlites already projector style? I have a 2016 Ram Longhorn 1500 with projector, but brighter 9005 bulbs, and gonna put some LED's in them... just gotta find the proper ones to fit the housing(the fans on the back of the LED's won't fit the housings) so only able to do the fog lites for now

Putco makes them specifically for ram headlights. Uses a flexible heat sync instead. Have put quite a few in.

MK4TDI · Dec 16, 2020

08arcticcat said:
After burning out my mini h1 headlights i had built for me back in 2012/13 i decided to try my hand at making my own.

I have been running 55w hid in the morimoto mini h1 for 8 years and the output was declining down to where its terrible. Finally i decided to do something about it.

I ordered a set of morimot D2S 5.0 projectors, some 4500K D2H bulbs, the wiring, and the butyl from Winnipeg HID on black friday, he has been awesome to deal with.

Your going to like those projectors, been running them in my duramax for over a year now. Crisp and clear lights with an excellent cutoff.

In my Chevy halfer I have the 3" FXR projectors and they are equally as good. They spread light a little wider but dont have as nice of cutoff.

Mzingel · Jan 28, 2021

Can never go wrong with projectors. 2.5mh1's, only 35w but bright enough. Have a switch to turn all on low beam.

ippielb · Jan 28, 2021

I absolutely need this done on my truck. my HID's are going on 10 years old and slowly dying one at a time. How much does it cost to get someone to retrofit lights for you? I'll have to get all new housings as well. I cant adjust mine anymore.

Mzingel · Jan 30, 2021

It depends what you want really.
The more bells and whistles the more they cost.
The lights I posted were under 300$ in parts. And took a couple evenings at work (camp job) to complete. The wiring took a while because of the halo ring running lights that are also switchback led turn signals.

Lunch_Box · Jan 31, 2021

Nice job. Ive built a couple pairs for my truck. The one set with dual projectors are in the truck currently, the other set is collecting dust. Lots of work but worth it.

Projector headlight build

08arcticcat

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