I've been looking into this (came across this mod when I was overseas) as a solution for running HID's in my STI - I must be getting old as I find the factory halogens woeful. HID conversions to the OEM reflectors just throw light everywhere and have eye straining hotspots in the foreground, not to mention annoying every other person on the road.

The solution is to retrofit proper HID projector lenses to the lamp housings.



This conversion to the OEM housings gives you the proper light distribution required to legally run HID's, they have Hi/lo beams, proper beam cut off and do not glare if adjusted correctly.

Low beam


High beam


Note: Both images above show LHD light patterns - be sure to order RHD projectors if you want to do this mod.

The only change I intend to make to the mod is to use Plasti Dip to tint the factory reflector to stop the internal reflections inside the lamp housing.

These are the projector units I bought:



Once they arrive I'll post up the whole conversion process.

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Will be keeping an eye on this, will the projector units have self-levelling etc.?

There is no ADR requirement for auto levelling (adaptive headlamps) nor headlamp washers - it's a misconception due to European ECE standards requiring headlamp washers.

ADR 77 - Gas discharge lamps Vehicle Standard (Australian Design Rule 77/00 - Gas Discharge Headlamps) 2006

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does it get hot inside the housing? Just wondering if Plastidip can handle the heat

That suby is so hot btw

Right, thanks for clearing that up!

The plasti dip should be fine - I'll suck it and see.

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So my projector kit arrived today........ Without further a-do! (Stock GC headlights are crap!)

Apologies in advance for the Iphone spec photo's - I took the pics as I went.

The goal is to replace the good (?) old Halogen H4 bulb with a Bi-xenon projector

I'm not going to bother with instructions on how to remove the headlamps for a GC8 - if you can't work it out then I suggest you don't try to do this mod!

Old v New


The Projector Kit I purchased included 2 x 3 inch Hi/lo projectors, CCFL halo's (switched with the park lamps), 2 x ballasts, Wiring harness and fitting kit. All up the kit was about $150 delivered. **Be sure to order the Right-hand drive version!!**

Righto - Let's crack on....... First we need to remove the headlamp's glass lens. This involves an oven, some gloves and a hobby knife - what could possibly go wrong?

Pre-heat the oven to 160c
Whilst the oven is heating up - remove the 5 steel clips holding the lens to the headlamp body. (flat tip screwdriver does the job)



Put 1 headlamp in the oven for 5 minutes - remove with heat proof gloves.
The sealant holding the lens in place will now have the consistency of chewing gum. Use either a plastic wedge or a screwdriver to gently pry the lens from the lamp body. Use the hobby knife to trim the sealant as you go to reduce the stringiness/ mess.

Once the lens is removed, unscrew the trim piece - yours are probably chromed, my headlamps are aftermarket black crystal jobbies (in my lamps - 1 phillips head screw retains the bezel)



Next we need to remove the H4 bulb shield (one phillips head screw).



Shield removed



At this point I cleaned the lamp reflector with Isopropyl Alcohol and applied 2 coats of black Plasti-dip - you can skip this step if you want your lamps to the retain a semi factory look.

Plasti-dipped reflector - I like the look it gives (scroll down to the bottom)


Mounting the projector is pretty straight forward, the kit comes with H4 adapters - note that the projectors are solidly mounted to the lens housing via the adapter, your headlamp aiming should be the same as before the conversion (mine was).



Refit the lamps outer trim



Take a minute to clean the inside of your headlamps lenses with glass cleaner - followed by isopropyl alcohol to remove any residue.

Refitting the lens is simply a matter of sitting the lens on the lamp body and placing the assembly into the oven again for 5-7 minutes, once hot you can gently push the glass down into the sealant bed. refit the metal clips whilst everything is still hot to ensure a good seal.

Ta da! You are done!

You should now have a pair of lamps that look something like this:



Re-fit the lamps to your car and wire up the lights, mine had a really good wiring harness supplied - no cutting required and the lamps draw directly off the battery via a relay. Hi/lo switching is via an internal solenoid inside each projector - the harness included the interface for the solenoids, making everything plug and play. Super simple!

End result



Low beam (yes - I have a park light out!):



Conclusion:

After a quick test drive (I finished the job after midnight!), I can say this conversion is the ducks nuts - the low beam throws far more light on the road, has far better light pattern and sharp cutoff (unlike the H4's) - the high beam is literally night sun spec!

I'll take some shots of the beam patterns tomorrow night (and with my good camera!).

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will the plasti-dip handle the head produced from the headlights okay? guess time will tell

does look great though

Wow that looks incredible!

Can you chuck a link up from where you bought yours from please?

Another awesome DIY Ross!

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Huge range of extinguisher brackets for cars!

http://kap.industries/

Linky: 3" HID Projector kit -Ebay

They have Angel eye park lights and red 'Devil Eyes' - I haven't wired them up. I will connect the Angel eyes but not the Devil eyes......

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