DIY Projector lens retrofit into H6054/7x6/MR2 headlight housing
This may be of interest to some on here, my DIY projector retrofit.
As i'm sure some of you are aware the standard headlight output from an MR2 is pretty pants, of course you can buy expensive philips bulbs, osram nightbreakers etc but nothing compares to the light output from a 'Projector' headlight and i'm not talking about the cheap stuff you find on ebay.
Unfortunately there is no off the shelf retrofit projector headlight for the MR2 although due to the fact the same style of light is used in many other vehicles (search H6054, 7x6) many other people have already done retrofits making it that little bit easier.
Anyway on with the show... First up some donor headlights, unfortunately these ones had markings on the glass which I didn't realise when I ordered at the time however it has minimal impact on the light output (i've tested)
When buying donor lights some are all plastic with polycarb lens or in my case metal and glass just depends what is easier for you to get hold off.
The parts came from Vikom here in Australia who appear to be a reseller or in some way connected with the retrofit source in the US.
Parts ordered were the Morimoto mini D2S with associated bulbs and H4 wiring loom, also ordered Apollo 2 shrouds. The shrouds serve no real purpose other than cover up the projector assembly or in my case I will also be mounting LED rings behind and at the front.
The mini D2S is actually designed to be a 'plug and play' projector for H4 headlights, it's designed to slot straight into the H4 bulb socket, so providing your headlight is deep enough that is all you would need to do and you're done! unfortunately this is most certainly not the case here.
Oven baked headlights and voilà
Old computer desk serving as test rig, marked the walls to see where the unmodified headlight would shine so I knew where about's to fix the projector in place
Time to start cutting up the headlight......
Still not enough....
As I now had a massive hole in the rear of the headlight I needed to secure it in place for alignment and long enough for the epoxy to set, in order to do this I decided to use some PVC pipe and the original H4 locking nut like so
The shrouds needed significant modding in order to fit before and after
Once I was happy with projector alignment I removed them again to allow me to paint the headlight reflector bowl.
Cutouts on the shrouds is to allow for the LED ring wiring
The exposed parts around the pvc tube would be filled with epoxy after painting and projector installation as the exposed parts of the projector would them also be bonded in place
All painted, not sure how good it will look when all assembled but most definitely won't be worse than standard
Test fit
Projector final installation
This is as far as i've got, still waiting on my rear LED ring before I can fit the shroud and seal the headlight.
Before someone asks "why bother" this is why
Halogen (full beam actually no low beam shot)
Projector low beam
I think those pics speak for themselves