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chopsmitty
04-15-2017, 03:22 PM
Recently had a ballast go out so time has come to replace everything! Both projector cups (reflectors) were burnt... bad ballast and the bulbs were looking old. Bought the Retro-Quik: Universal kit from THE RETROFIT SOURCE. Upgraded to the 50w ballasts and the Morimoto H1:XB 5500k bulbs. RQ Hardware Universal brackets were also included.

This is everything I went through to get this installed the best way I could figure...

chopsmitty
04-15-2017, 03:24 PM
Here's a shot of the burnt reflectors:
https://farm5.staticflickr.com/4396/36537234486_1de0b8b612_c.jpg (https://flic.kr/p/XEESSJ)20170414_162136 (https://flic.kr/p/XEESSJ) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

Bye Bye!

chopsmitty
04-15-2017, 03:30 PM
The kit was packaged very nicely.
https://farm5.staticflickr.com/4370/35748468644_287a1577ac_c.jpg (https://flic.kr/p/WsYfgE)20170413_085415 (https://flic.kr/p/WsYfgE) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

Did a complete inventory and mocked up some of the wiring and found that I'd need a pig tail to power up the ballast.
https://farm5.staticflickr.com/4335/36415199752_96ec342271_c.jpg (https://flic.kr/p/XtTqcA)20170413_095818 (https://flic.kr/p/XtTqcA) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr
Asked for a 9006 headlight pig tail at NAPA. They were in stock (even in Hawaii!)

chopsmitty
04-15-2017, 03:32 PM
Removed both headlights
https://farm5.staticflickr.com/4365/35748476324_5d7be6d7b0_c.jpg (https://flic.kr/p/WsYhy5)20170414_110004 (https://flic.kr/p/WsYhy5) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

Here's a shot of the typical condition of the wiring in these old cars (the Hawaiian sun may be a little more intense than other locations)
https://farm5.staticflickr.com/4438/35748477224_de1ac04af7_c.jpg (https://flic.kr/p/WsYhPA)20170414_110910 (https://flic.kr/p/WsYhPA) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

chopsmitty
04-15-2017, 03:36 PM
Removed the ballast
https://farm5.staticflickr.com/4394/35748478244_0be507f163_c.jpg (https://flic.kr/p/WsYi8b)20170414_110916 (https://flic.kr/p/WsYi8b) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr
(You'll need a "security" torx bit.)

Unplug the auto leveler, ballast and high beam connector and set the ballast aside.
https://farm5.staticflickr.com/4438/35748480304_5da00f5c29_c.jpg (https://flic.kr/p/WsYiJG)20170414_111120 (https://flic.kr/p/WsYiJG) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

chopsmitty
04-15-2017, 03:40 PM
Next I removed all the bulbs and the projector assembly (it's removal has been covered on here a couple times).
https://farm5.staticflickr.com/4373/35748479254_8fe2e08877_c.jpg (https://flic.kr/p/WsYiqA)20170414_111001 (https://flic.kr/p/WsYiqA) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

With the projector removed and disassembled into components, I aligned the projector on the adapter plates as shown (pins tangent to the flat surface and centered)
https://farm5.staticflickr.com/4357/35748481354_45ebbe5af6_c.jpg (https://flic.kr/p/WsYj3N)20170414_113545 (https://flic.kr/p/WsYj3N) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

https://farm5.staticflickr.com/4409/35748482544_f858c53c22_c.jpg (https://flic.kr/p/WsYjpj)20170414_113834 (https://flic.kr/p/WsYjpj) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

Used blue tape and marked the hole.
https://farm5.staticflickr.com/4347/35748483854_27948ec181_c.jpg (https://flic.kr/p/WsYjMU)20170414_114501 (https://flic.kr/p/WsYjMU) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

chopsmitty
04-15-2017, 03:44 PM
https://farm5.staticflickr.com/4360/35748486204_6d556b1d8b_c.jpg (https://flic.kr/p/WsYkuq)20170414_114521 (https://flic.kr/p/WsYkuq) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

https://farm5.staticflickr.com/4376/35748484874_48774156b5_c.jpg (https://flic.kr/p/WsYk6u)20170414_114508 (https://flic.kr/p/WsYk6u) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

Using the stock projectors and holes drilled in the adapter plate, assemble the reflectors and the optic assembly.
https://farm5.staticflickr.com/4367/35748487234_a110f77d01_c.jpg (https://flic.kr/p/WsYkNb)20170414_114716 (https://flic.kr/p/WsYkNb) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

The reflector is the other set of holes. Easy!
https://farm5.staticflickr.com/4387/35748488454_b825c2511f_c.jpg (https://flic.kr/p/WsYmad)20170414_114809 (https://flic.kr/p/WsYmad) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

https://farm5.staticflickr.com/4362/35748490274_171be40bc2_c.jpg (https://flic.kr/p/WsYmGA)20170414_114908 (https://flic.kr/p/WsYmGA) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

Trip through the band saw and two more holes drilled...
https://farm5.staticflickr.com/4408/36583758445_cb3bfcb770_c.jpg (https://flic.kr/p/XJMjPX)20170414_115149 (https://flic.kr/p/XJMjPX) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

chopsmitty
04-15-2017, 03:48 PM
Completed brackets!
https://farm5.staticflickr.com/4422/36583765695_d9a9c7827b_c.jpg (https://flic.kr/p/XJMmYX)20170414_120905 (https://flic.kr/p/XJMmYX) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

Next to address the goofy half cut away stud on the top... (by the red sharpie mark)
https://farm5.staticflickr.com/4441/36583760235_91660a123d_c.jpg (https://flic.kr/p/XJMkmP)20170414_115819 (https://flic.kr/p/XJMkmP) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

https://farm5.staticflickr.com/4390/35774216833_4689f2e947_c.jpg (https://flic.kr/p/WvfdiX)20170414_120226 (https://flic.kr/p/WvfdiX) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

https://farm5.staticflickr.com/4418/36583761805_e8c1b18573_c.jpg (https://flic.kr/p/XJMkPT)20170414_120458 (https://flic.kr/p/XJMkPT) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

It's very brittle (mine broke a bit, but most remained intact) File flat.
https://farm5.staticflickr.com/4422/35774219003_dd31c8e46c_c.jpg (https://flic.kr/p/WvfdXn)20170414_120618 (https://flic.kr/p/WvfdXn) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

chopsmitty
04-15-2017, 03:50 PM
Verify the fit and make the second bracket.
https://farm5.staticflickr.com/4356/35774224753_ba28707e2d_c.jpg (https://flic.kr/p/WvffEv)20170414_121009 (https://flic.kr/p/WvffEv) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

chopsmitty
04-15-2017, 03:57 PM
Next I decided to cut out this section of plastic to give me more room to work...
https://farm5.staticflickr.com/4435/36583767925_57a59ec221_c.jpg (https://flic.kr/p/XJMnDp)20170414_123339 (https://flic.kr/p/XJMnDp) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr


Next (possibly the most important step)... There's no way you will get this completed projector assembly into the headlight housing in one piece. I chose to Tig weld a couple 4-40 bolts to the optic assembly to allow me to assemble the unit inside the headlight housing.
https://farm5.staticflickr.com/4344/35774227383_7bb235fa4d_c.jpg (https://flic.kr/p/WvfgrR)20170414_131427 (https://flic.kr/p/WvfgrR) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr


https://farm5.staticflickr.com/4424/36583769735_095013b3b4_c.jpg (https://flic.kr/p/XJMobB)20170414_131510 (https://flic.kr/p/XJMobB) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

Next had to make room for the 4-40 nuts.... (helps to have a Bridgeport - I'm a machinist by trade)
https://farm5.staticflickr.com/4386/35774230033_676a8603ce_c.jpg (https://flic.kr/p/Wvfhex)20170414_132202 (https://flic.kr/p/Wvfhex) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr


https://farm5.staticflickr.com/4433/36583771855_f13c163336_c.jpg (https://flic.kr/p/XJMoPa)20170414_133031 (https://flic.kr/p/XJMoPa) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

Assembled into the housing. Used lock washers. Yes, I only used two bolts. I believe it's plenty.

https://farm5.staticflickr.com/4376/36186857910_75cdaf9ba2_c.jpg (https://flic.kr/p/X8H78h)20170414_133722 (https://flic.kr/p/X8H78h) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

chopsmitty
04-15-2017, 03:59 PM
Installed bulbs
https://farm5.staticflickr.com/4418/35774233593_dc76de3dc9_c.jpg (https://flic.kr/p/WvfihV)20170414_134057 (https://flic.kr/p/WvfihV) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

https://farm5.staticflickr.com/4383/36186859240_ca539fb199_c.jpg (https://flic.kr/p/X8H7wd)20170414_134324 (https://flic.kr/p/X8H7wd) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

chopsmitty
04-15-2017, 04:03 PM
Next checked for clearance to locate the ballast. Decided it would fit fine on the bottom of the housing...
https://farm5.staticflickr.com/4442/36186859910_0246f11e42_c.jpg (https://flic.kr/p/X8H7HL)20170414_134549 (https://flic.kr/p/X8H7HL) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

Ballasts (at least one) were junk anyway, so I decided to use them as mounting plates for the new ballasts and to seal up the giant hole!
https://farm5.staticflickr.com/4435/36537228396_0b36e9382b_c.jpg (https://flic.kr/p/XEER4J)20170414_135127 (https://flic.kr/p/XEER4J) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

Just pry the electronics off the aluminum and throw it in the trash!

Mark for holes.
https://farm5.staticflickr.com/4422/36186860870_e39cbfc05c_c.jpg (https://flic.kr/p/X8H81j)20170414_135201 (https://flic.kr/p/X8H81j) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

I drilled and tapped for 4mm bolts (real short)
https://farm5.staticflickr.com/4432/36537229756_40cc0135af_c.jpg (https://flic.kr/p/XEERtb)20170414_140146 (https://flic.kr/p/XEERtb) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

chopsmitty
04-15-2017, 04:08 PM
Mark for hole (close to directly in the center - in line with the plug. There is some wiggle room here - don't sweat the location)
https://farm5.staticflickr.com/4415/36186861900_d504a91cf7_c.jpg (https://flic.kr/p/X8H8j5)20170414_140915 (https://flic.kr/p/X8H8j5) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

https://farm5.staticflickr.com/4406/36537231186_7aec347c4f_c.jpg (https://flic.kr/p/XEERTQ)20170414_141143 (https://flic.kr/p/XEERTQ) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

Next I verified which wire was +12v and which was ground. (On my car, a 2001 A4 with HID, the RED was +12v)
https://farm5.staticflickr.com/4393/36186862730_1874f32aff_c.jpg (https://flic.kr/p/X8H8yo)20170414_141724 (https://flic.kr/p/X8H8yo) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

Pretty darn basic wiring. If there are any questions here... you probably shouldn't be attempting this.

My lenses were a bit yellowed.
https://farm5.staticflickr.com/4426/36537232456_648961dd4b_c.jpg (https://flic.kr/p/XEESgJ)20170414_160543 (https://flic.kr/p/XEESgJ) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

So I hit them with a buffer and some light polish (actually Scratch Doctor in the orange container - Lol)
https://farm5.staticflickr.com/4371/36186863570_3bd21a29ac_c.jpg (https://flic.kr/p/X8H8NS)20170414_160906 (https://flic.kr/p/X8H8NS) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr
Worked great!

chopsmitty
04-15-2017, 04:12 PM
Complete the process for the other side and voila!
https://farm5.staticflickr.com/4347/36186864050_4709494542_c.jpg (https://flic.kr/p/X8H8X9)20170414_161541 (https://flic.kr/p/X8H8X9) by Greg Green (https://www.flickr.com/photos/153792397@N03/), on Flickr

Took me about 4 hours, start to finish. The TRS kit was $285 and the results are stunning. My photo skills in the dark are less than desirable, but I can tell you all these things are nice. Played well with the CanBus - no 'bulb out' indicators. Best of luck!!

maxiz1
04-15-2017, 04:45 PM
Great work!!! I'm just curious on why you need to dismantle the projector to install it. I never had to do that. The whole assembly could go in with no sweat.

chopsmitty
04-15-2017, 05:10 PM
Without the bracket attached to the Mini H1, it'll slip right in. With the bracket - no way. Think about it, the stocker has to be disassembled to be removed.

andyrew
04-15-2017, 05:26 PM
Holy crap, that wiring is horrid! Someone was putting way to much juice through the headlights.

maxiz1
04-15-2017, 06:06 PM
Without the bracket attached to the Mini H1, it'll slip right in. With the bracket - no way. Think about it, the stocker has to be disassembled to be removed.

Correct because your bracket attaches in between the lens holder and the reflector bowl. Mine is at the front where I got to install the bracket 1st then slide in the whole projector. The disadvantage of mine is the lens sits slightly behind the housing lip, which i think does not make any difference in terms of looks and performance.

rodgertherabit
04-24-2017, 06:56 AM
I make/sell brackets for this exact application fyi.

plug and play ;-)

Froggzy
01-03-2018, 02:30 PM
Hey! Any possiblity that you still have the images and can post them with something else that photobucket, so the images show up again?

GOODBYNAAIR
01-03-2018, 05:51 PM
Update ur photos

Sent from my SAMSUNG-SM-G920A using Audizine mobile app (http://r.tapatalk.com/byo?rid=87676)

chopsmitty
01-16-2018, 11:35 AM
Photos updated. Isn't it amazing that photobucket essentially killed a whole wealth of information by no longer allowing third party sharing!?!

My headlights are still kicking a&&! Best thing I've done to the car yet.

kpadlina
08-31-2018, 08:58 PM
I noticed you mounted these by placing the mount you made between the lens and the reflector bowl. does this affect the beam pattern being how the bowl is now further away from the lens?

chopsmitty
11-12-2018, 12:08 AM
Nope. The beam pattern is perfect. Still working great!!!!!

joeonthedownlow
02-07-2019, 12:39 PM
Did the same thing with the Mirimoto Mini H1 7.0s on my A4 B5 and just have to say a huge improvement over Halogens. I just get the bulb out error since I didnít get the canbus. Really no issues so far though. Hopefully they will be reliable and last a long time.

105325 Before

105326 After

joeonthedownlow
02-07-2019, 07:47 PM
105375


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