My HID Retrofit (lots of pics)

So, as some of you know, two years ago I began the crazy project of retrofitting a set of Infiniti FX45 bi-xenon HID projectors into a set of Cobalt SS headlights. Despite the long, and sometimes painful process, I still consider this to be one of the best mods I've ever done. The spread on the light is amazing, and the high beams are like nothing else... and to top it off, it doesn't blind other drivers due to the OEM style cut off.

And so... here is the process;

The stock reflector bowl;




First cut;



Ground the profile a bit closer;




Initial mock up of the projector;





It was at this point that I had to make a decision.... how to finish off the bowl. After many weeks of staring at the mocked up projector (for hours on end, with a drawing pad), I decided to go with a custom silver bezel with halo rings. I found a set that were almost the same color as my HID bulbs; 5000k halo's with 4300k HID's.

Halo rings;





Halo's lit up;





Bezel, with trim temporarily tapes on;



Halo with inner trim epoxied to fit projector;


Projector epoxied in place, after test fit on car;


Bezel on projector;



Test fit in housing;



Halo's on;





And, finished!






Note that since this last picture, I have added a small silver wire guard to the 'break' in the halo rings.

Oh... and for those that are interested in doing something similar; this is only half the battle. The wiring for all this was a bit of a nightmare... and I'm just finally getting to the process of cleaning it up.

This winter, I'll be modifying the stock fuse box to eliminate external fuse holders, and adding a relay module in the fender well. Also, I'll be adding a 'low beam kill switch' to the works, so that I can turn off my headlights on the highway, but only if the fogs are on (Maidstone is bad for thick fog).

Nice write up. This has been on my to do list for a while now, maybe next year lol.

Maybe check out this site for some good prices, and good products;
http://store.theretrofitsource.com/index.php

They have a good selection of bezels and shrouds, as well as wiring solutions that should make the install go a lot more smooth.

Sweet, I'd love to replace the projectors on my car with some TSX ones. I like the style of my headlight, just not the light output.

Nice nice! A pinch better then my old Gen 1s i think. lol