This is that retrofit thread we talked about!
03-30-2013, 10:42 PM
#132
Senior Member
03-30-2013, 10:57 PM
#133
In Dale we trust.
Let me know, I'll paypal you a little currency if you need 
Once you're done you should definitely make a full writeup with whats in this thread, maybe get it stickied.
Picking up the headlights tomorrow at noon so I will get cracking on it Sunday night
Once you're done you should definitely make a full writeup with whats in this thread, maybe get it stickied.
Picking up the headlights tomorrow at noon so I will get cracking on it Sunday night
03-30-2013, 11:10 PM
#134
Senior Member
Here are a few notes from todays work:
1) Use screws instead of JB Steelstik. At first thought Steelstik seems like an easy way to do it but I couldn't get it to hold even after it had set.
2) Since the epoxy is really what holds the projector in the end I chose to drill 9/64 holes and thread #8 screws into the reflector buckets which worked perfect.
3) Be sure that the bulb is seated correctly! More on that later........
4) Before removing your halogens park your truck in front of a wall (I was 15' back) and make reference marks on the wall with tape. Mark the "steps" (if you can really call them that) and mark the flat spots of the beam. Now take a tape measure and see measure the distance off of the ground to the lower step on the driver's side. Move to the left about 10' and make a small reference mark on the wall. Now put tape from that reference mark to the tape you had originally put up. If you're truck is somewhat level this should give you a decent visual aid in leveling the beam rotation.
5) Don't screw the screws in too tight that hold the projector to the reflector bucket. You will strip them!
6) Before you JB weld the projector to the bucket make sure to cover all vent holes in the projector as well as the solenoid mechanism to prevent any epoxy from leaking into them. Do this with aluminum tape.
7) I decided not to make shrouds but if you do make shrouds a good way is to use paper and form a cylinder around the shroud. Tape it together and slide it towards the reflector bucket until you hit it. Then make an outline around the paper shroud extension and trim it. Keep doing this until it's satisfactory. You can attach the extensions to the shrouds several different ways; I've seen different methods using rivets and epoxy. I don't know this to be true but I've been warned about using super glue to attach the shrouds because it'll release fumes which will fog up the headlight lens and/or the projector.
8) I don't know much about attaching halos to shrouds mainly because I'm assuming all shrouds will need to have it done in different ways. I simply made some adapters that the halos are JB welded to and I'll JB weld the adapters to the shroud. Simple and effective.
9) Once again....... PATIENCE IS KEY!!! Take your time aligning the projectors and it'll work out for you in the end.
Here are a few issues I had today that cost me some time:
1) The bulbs would not fit into the FXR projectors without being modified. Once you get the bulbs you'll see that they have what I'm going to call a "bulb holder" that appears to reinforce the bulb to the base. If you look closely at it you'll see that the piece is actually two pieces welded together. Where it was welded together it was too large to actually fit into the FXR's hole. After realizing what was wrong I sanded it down with my dremel until it fit into the hole. This was on both bulbs and neither would fit in either projector to begin with. I guess this is why they say OEM bulbs are the best.
2) On one of the projectors I had to slightly modify the casting the bulb seats against. There are three tabs on each projector that have been sanded down (I'm assuming at TRS) and one of them was not sanded. I sanded it down to match the others but this is also the projector that didn't have a sharp cutoff. I'm hoping that's just a bulb seating issue but we shall see.
3) I also had to drill out the mounting holes on one of the projectors because the #8 screws wouldn't fit through it. The other projector was fine.
That's all I have for now. If I think about anything else I'll post.
1) Use screws instead of JB Steelstik. At first thought Steelstik seems like an easy way to do it but I couldn't get it to hold even after it had set.
2) Since the epoxy is really what holds the projector in the end I chose to drill 9/64 holes and thread #8 screws into the reflector buckets which worked perfect.
3) Be sure that the bulb is seated correctly! More on that later........
4) Before removing your halogens park your truck in front of a wall (I was 15' back) and make reference marks on the wall with tape. Mark the "steps" (if you can really call them that) and mark the flat spots of the beam. Now take a tape measure and see measure the distance off of the ground to the lower step on the driver's side. Move to the left about 10' and make a small reference mark on the wall. Now put tape from that reference mark to the tape you had originally put up. If you're truck is somewhat level this should give you a decent visual aid in leveling the beam rotation.
5) Don't screw the screws in too tight that hold the projector to the reflector bucket. You will strip them!
6) Before you JB weld the projector to the bucket make sure to cover all vent holes in the projector as well as the solenoid mechanism to prevent any epoxy from leaking into them. Do this with aluminum tape.
7) I decided not to make shrouds but if you do make shrouds a good way is to use paper and form a cylinder around the shroud. Tape it together and slide it towards the reflector bucket until you hit it. Then make an outline around the paper shroud extension and trim it. Keep doing this until it's satisfactory. You can attach the extensions to the shrouds several different ways; I've seen different methods using rivets and epoxy. I don't know this to be true but I've been warned about using super glue to attach the shrouds because it'll release fumes which will fog up the headlight lens and/or the projector.
8) I don't know much about attaching halos to shrouds mainly because I'm assuming all shrouds will need to have it done in different ways. I simply made some adapters that the halos are JB welded to and I'll JB weld the adapters to the shroud. Simple and effective.
9) Once again....... PATIENCE IS KEY!!! Take your time aligning the projectors and it'll work out for you in the end.
Here are a few issues I had today that cost me some time:
1) The bulbs would not fit into the FXR projectors without being modified. Once you get the bulbs you'll see that they have what I'm going to call a "bulb holder" that appears to reinforce the bulb to the base. If you look closely at it you'll see that the piece is actually two pieces welded together. Where it was welded together it was too large to actually fit into the FXR's hole. After realizing what was wrong I sanded it down with my dremel until it fit into the hole. This was on both bulbs and neither would fit in either projector to begin with. I guess this is why they say OEM bulbs are the best.
2) On one of the projectors I had to slightly modify the casting the bulb seats against. There are three tabs on each projector that have been sanded down (I'm assuming at TRS) and one of them was not sanded. I sanded it down to match the others but this is also the projector that didn't have a sharp cutoff. I'm hoping that's just a bulb seating issue but we shall see.
3) I also had to drill out the mounting holes on one of the projectors because the #8 screws wouldn't fit through it. The other projector was fine.
That's all I have for now. If I think about anything else I'll post.
03-30-2013, 11:12 PM
#135
Senior Member
03-30-2013, 11:22 PM
#136
Love Turbo V6 & Coyote V8
Dam.... Only 2 pics of your wife g/f mistress 2011limited#288!!!????!! once I saw her fine *** I quickly went through all 14 pages looking for more pictures since you said you will try to get her in more pics...... hahahahahahaha Sorry for going off topic... Now I gotta go back and read the whole thread now....... hahahahahaha
03-30-2013, 11:26 PM
#137
One Clean Machine
iTrader: (5)
Lookin good soo far FX4!
03-31-2013, 09:41 AM
#138
Modification Addict
dam.... Only 2 pics of your wife g/f mistress 2011limited#288!!!????!! Once i saw her fine *** i quickly went through all 14 pages looking for more pictures since you said you will try to get her in more pics...... Hahahahahahaha sorry for going off topic... Now i gotta go back and read the whole thread now....... Hahahahahaha
