I'm doing a conversion from two-piece halogens to one-piece HID housings with HID. It's turning out to be a quite nice solution and cost effective.
Conversion Info.
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I've spent a considerable amount of time debating on how I should go about this conversion and so I though I'd post my plan just in case I'm about to set the redrocket on fire. I guess this could also serve as a doc one one of the many ways to update pre 99.5 cars.
1. Hella(Phillips) Gen 3 D2s ballasts using low beam as power source.
2. S4 HID housings with bottoms open.
3. No purchase of "Bosch to Valeo" adapter harness.
4. Clean install, ballasts hidden.
What's interesting about this particular conversion is that there is no need to purchase an adapter harness because the only power you need to pass into the housings other than the HID socket cable is the high beam. The Ballasts will be powered externally so why adapt to a new style harness when you're gonna splice anyway? So, no need to spend $50 bucks on a plastic socket with some wires coming out of it!
The plugs on the two-piece lights are kind of cool. If you rip apart all the plastic garbage you're left with a mini plug and play, mix and match set of wires that are easy to configure. In 3 seconds you have a direct plug to the high beams and a splice of the low beam to the 9006 connector to plug into the ballasts. The next step is getting those two power sources into the housing through the bottom. The S4 housing comes with an open bottom which will have to be sealed anyway.
I will seal the bottom of the housings with a flat plastic plate. But before this I can drill a 3/8 inch hole in the bottom of it and cut a thin line from the hole to the edge of this bottom cover. The hole is for the D2s wire(about 1/4 inch thick) and the two high-beam wires to pass through. The line cut to the side is to actually pass the wires over to the hole. If you want to do this without cutting a thin line through the plastic bottom cover, you'd have to make the hole about 1 1/4 inch in diameter to pass the huge D2s connector through it and this is a biotch to seal after.
After the wires are passed through, it's time to use that epoxy stuff I hear about to seal everything up.
At this point, is every thing is properly insulated, you've converted with properly sealed projectors, hidden ballasts,(I found some awesome spots)and no wiring harness.
This is permanent, but so is going to one piece in the first place.
Edit: I found this stuff called Automotive "Goop". It's very close to bead sealer, and worked great.
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