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Halogen to Xenon upgrade, Quad projector, FX-R retrofit
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<blockquote data-quote="aidilj" data-source="post: 522538" data-attributes="member: 20536"><p>Start of second section</p><p></p><p>Headlights out of car</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3422_G.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>AL logo</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3427.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Bulbs and holder out</p><p>Grey holder for low beam, black for high beam</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3428.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Bowls out, as also pointed by xcrave that removing the bowl can be hard. I did it by removing the black plastic then clipping off the levelling servo from the front</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3431_G.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Angel eyes out</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3455.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Fitting test</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3440.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3437.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>FX-R is mounted in the bowl with two screws. One as pivot point for rotational adjustment</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3465.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>This spray is highly recommended</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3458.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Painted with satin black</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/c27d9f9d.png" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Angel eyes installed</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3485_G.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>The replica shroud was hacked thoroughly to fit the angel eyes. No modification to the OEM shroud</p><p>Initial hack</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/559a14e8.png" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Whats left of the shroud</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3519_G.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>It turns out that double-sided tape is not good enough so the angel eyes are JBed (JB welded)</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3521.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Electricals</p><p></p><p>A simple circuit was designed to handle the existing control input from the car. When flashing with the low beam off, activate the halogen and its projector shutter. But when low beam is on, high beam or flash activates the bi-xenon shutter. Schematic as follows</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/46abe51d.png" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Circuit produced</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3516.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Another set of relay is used to convert the 3 wire AL solenoid to 2 wire input. We need to enable the strong pull solenoid momentarily before then activating the weak solenoid to hold the shutter down. Schematic follows, the capacitor would allow short energization of relay until it is fully charged, resistor is to discharge the capacitor</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/bosch_solenoid_wiring1.gif" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>The relay set</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/ecc3bdf2.png" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Capacitor for HID to solve flickering problem</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3526.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Capacitor for angel eyes, also for flickering problem</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3525.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Before</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3388.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>After</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3509.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Output comparison</p><p></p><p>Comparison between 55W halogen with 35W HID, HID is more efficient because most energy is converted to light while halogen radiates a lot of heat</p><p></p><p>Low beam before (halogen)</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/output/IMG_3397.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Low beam after (HID)</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/output/IMG_3530.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>High beam before (2X 55W halogen)</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/output/IMG_3406.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>High beam after (bi-xenon shutter)</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/output/IMG_3535.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Done</p><p><img src="http://i791.photobucket.com/albums/yy197/aidilj/projector/3456e1f7.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>All in all I'm okay with the result, not very happy with the high beam and I'm blaming the cheap bulb for that. Suspecting that the arc chamber is skewed causing the light to be off center. Will try to get new proper bulbs and keep these as spares. Probably going for 55W ballast next time for crazy output. Hope this would help anybody looking for a guide or help.</p><p></p><p>Cheers</p><p>Aidil</p></blockquote><p></p>
[QUOTE="aidilj, post: 522538, member: 20536"] Start of second section Headlights out of car [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3422_G.jpg[/IMG] AL logo [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3427.jpg[/IMG] Bulbs and holder out Grey holder for low beam, black for high beam [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3428.jpg[/IMG] Bowls out, as also pointed by xcrave that removing the bowl can be hard. I did it by removing the black plastic then clipping off the levelling servo from the front [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3431_G.jpg[/IMG] Angel eyes out [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3455.jpg[/IMG] Fitting test [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3440.jpg[/IMG] [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3437.jpg[/IMG] FX-R is mounted in the bowl with two screws. One as pivot point for rotational adjustment [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3465.jpg[/IMG] This spray is highly recommended [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3458.jpg[/IMG] Painted with satin black [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/c27d9f9d.png[/IMG] Angel eyes installed [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3485_G.jpg[/IMG] The replica shroud was hacked thoroughly to fit the angel eyes. No modification to the OEM shroud Initial hack [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/559a14e8.png[/IMG] Whats left of the shroud [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3519_G.jpg[/IMG] It turns out that double-sided tape is not good enough so the angel eyes are JBed (JB welded) [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3521.jpg[/IMG] Electricals A simple circuit was designed to handle the existing control input from the car. When flashing with the low beam off, activate the halogen and its projector shutter. But when low beam is on, high beam or flash activates the bi-xenon shutter. Schematic as follows [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/46abe51d.png[/IMG] Circuit produced [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3516.jpg[/IMG] Another set of relay is used to convert the 3 wire AL solenoid to 2 wire input. We need to enable the strong pull solenoid momentarily before then activating the weak solenoid to hold the shutter down. Schematic follows, the capacitor would allow short energization of relay until it is fully charged, resistor is to discharge the capacitor [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/bosch_solenoid_wiring1.gif[/IMG] The relay set [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/ecc3bdf2.png[/IMG] Capacitor for HID to solve flickering problem [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3526.jpg[/IMG] Capacitor for angel eyes, also for flickering problem [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3525.jpg[/IMG] Before [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3388.jpg[/IMG] After [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/IMG_3509.jpg[/IMG] Output comparison Comparison between 55W halogen with 35W HID, HID is more efficient because most energy is converted to light while halogen radiates a lot of heat Low beam before (halogen) [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/output/IMG_3397.jpg[/IMG] Low beam after (HID) [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/output/IMG_3530.jpg[/IMG] High beam before (2X 55W halogen) [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/output/IMG_3406.jpg[/IMG] High beam after (bi-xenon shutter) [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/output/IMG_3535.jpg[/IMG] Done [IMG]http://i791.photobucket.com/albums/yy197/aidilj/projector/3456e1f7.jpg[/IMG] All in all I'm okay with the result, not very happy with the high beam and I'm blaming the cheap bulb for that. Suspecting that the arc chamber is skewed causing the light to be off center. Will try to get new proper bulbs and keep these as spares. Probably going for 55W ballast next time for crazy output. Hope this would help anybody looking for a guide or help. Cheers Aidil [/QUOTE]
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