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bdutton

4th Gen Projector Retrofit

I had a few extra bucks from doing some overtime two weeks ago so I decided to order the Motocycle: Stage 2 Dual kit from www.theretrofitsource.com. This will be my build and install write up thread.

 

The kit includes two bi-xenon Morimoto Mini H1 LHD 7.0 projectors, two H1 XB 4500K bulbs, 1 H4 dual output harness, two 35 watt Morimoto XB35 ballasts (plus the Amp igniters), two Mini Gatling Gun shrouds and 1 package of black RetroRubber headlight sealant.

 

I will be building a vacuum forming table to make a new lens for the headlight since projectors and fluted glass don't mix. I will include that process here as well.

 

Pictures in order of which they were removed from the box. Everything looks to be amazing quality. The harness pieces all snap together with an audible click so you know it's fully seated. The last picture is everything laid out so I can figure where everything goes. It's going to be interesting figuring out where to hide all this additional wiring!

 

Vacuum table pictures coming as soon as pick up the pieces necessary to so. Thanks for looking!c4720e432955c61e04d2be04deb90a2a.jpgc1833eeda885222095466650d28c79a5.jpgca9e96baa100127eac08cb3ada63a011.jpg6a55ef75d4b5d573aa99411e0717d79f.jpg494031fdb8ee507eb37e2319f5501455.jpgccb0147a00fd97b9d03dc6509196e627.jpg924f4ac6649337a68da62ad733c825d0.jpg121e1bfafbce19344eba43f7dd3762e7.jpg5b7747a691d2a559ecea4c5560e67be9.jpg43ba2dc7289f15831cf3b06c2b2bd60c.jpg

 

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Hit my first snag of this project... The h4 lock ring included with the kit is a different pattern than the factory Honda bulbs15752178d9e2a7f07a1294438ee08fd0.jpg

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They are different, you have to trim the two lower tabs for them to work then get an adapter plate.

 

http://m.ebay.com/itm/H4-ADAPTER-RINGS-HONDA-VFR750-VFR800-VFR-750-VFR-800-Lifetime-Warranty-/132129416824?nav=SEARCH

 

Alternatively you can ruin your original bulbs and take out the bulb and base to leave just the ring. May take a slight bit of dremel work to get it fitting right.

 

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They are different, you have to trim the two lower tabs for them to work then get an adapter plate.
 
http://m.ebay.com/itm/H4-ADAPTER-RINGS-HONDA-VFR750-VFR800-VFR-750-VFR-800-Lifetime-Warranty-/132129416824?nav=SEARCH
 
Alternatively you can ruin your original bulbs and take out the bulb and base to leave just the ring. May take a slight bit of dremel work to get it fitting right.
 

I decided that I'm going to Dremel the actual plastic on the back side of the reflector after doing a test fit just now. I'm also going to have to rename the bike. Up until this point, I have been referring to it as The Red Rocket (a reference to a certain South Park episode), but now I think I'll have to call it Wall-E!
2cbe0fadabbe120bbcbfb5b54c30cb90.jpg

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Did the reflector bucket come out separately? All the retrofits I see normally have painted reflector. If it comes out then that makes life easier.

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9 hours ago, bdutton said:


I decided that I'm going to Dremel the actual plastic on the back side of the reflector after doing a test fit just now. I'm also going to have to rename the bike. Up until this point, I have been referring to it as The Red Rocket (a reference to a certain South Park episode), but now I think I'll have to call it Wall-E!
2cbe0fadabbe120bbcbfb5b54c30cb90.jpg

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I shall be following your progress with interest.  Especially the vacuum table bit!  I've been a Retrofit Source customer for many years (they were always good, even before they developed their excellent Morimoto product line), but what has stopped me doing anything with my FP's headlights was "the lens issue"...  My vague plan was always to somehow grind down and progressively polish the inside of the glass lens (only a 3" circle would be necessary) until I'd achieved two unfluted sections the projectors could peek through, but I never moved much beyond the "musing" stage! 

 

The reflectors are separate and removable, and at least on the 5th gen are necessary to maintain the OEM adjustment mechanism.  I have baked a 3rd gen headlight apart, but I don't recall if it is designed to use the same kind of adjustment mechanism as the 5th gen.  I think leaving the reflectors in place helps avoid the "Wall-E" look, too, but that's really a question of aesthetics.

 

Good luck with the lens-forming.  Too bad the 3rd and 4th gen headlights are different (significantly so?), or I'd ask you to make me one!

 

Ciao,

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Making progress! Once you have the lens separated from the housing and most of the butyl rubber removed, trace the outline of the lens onto a large piece of wood. I bought a 24x24 piece of 1/2 or 3/4 MDF. Using a rotozip, remove the material inside the like you just traced. Save the cutout, it will be useful later but the piece with the hole that you just made is the important one. I bought a 4 lb bag of plaster of Paris, could've used a little more though. The acrylic is 24x18"x .08. The wooden frame is made of 1.5"x 3/4"x 8 ft. I used poplar but you can use whatever is available. You'll need two pieces of this size. That's all I have for an update at this time due to having to let the plaster set and I have to get ready for work. Hopefully I'll actually be able to form the lens tomorrow!0a5427bad6129b1157c73c674bcba9d5.jpgeda7f8a0a39ff12e887b70b32e2ba2cb.jpg9ded12805cc6c37d3fe0d8ec4ddda886.jpg78681c5fad177ffc6dcb75e7e48e7e97.jpg8bc0c01919ce5052559af4e00e21ede0.jpge1d72acada32076cb418b6aeeeb75486.jpgb18a69bfade07fc1bcc05d477f6ad6d0.jpg

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More updates for everybody! Going to use black silicone/RTV I think to seal up the lens. I don't like the idea of having to bake it when there are the wires for the high beam shutter in the housing. I'll provide a detailed description of exactly what I did tomorrow along with some night shots.345e0196ad09a9b3c684766cf838ed16.jpg7e66be2285fddead89d590c0b8a625e2.jpgf67fdcae9a39d32f427e2df8c58ef8a0.jpge6349a529c45d2d0c5828a28841147b5.jpgc58c9d1e3ee189387e2e1444a0c7c095.jpg4d904b6949d29398f874a3824470b57d.jpg6589049bb264f28752167e187b8ed4d3.jpg19ebea03bdb712247ae308f4f1e39650.jpg201d11536eb3e8375871a59884ecfd9b.jpg

16e030c6421adad39c4cdf5cf3cd9403.jpg

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I would still use the sealant TRS sent. Wire insulation is rated for certain temperatures, normally marked on the wire. I'm sure they make sure that 7 minutes in the oven won't hurt anything. I know a number of people who have baked lights during retrofits, never an issue.

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I would still use the sealant TRS sent. Wire insulation is rated for certain temperatures, normally marked on the wire. I'm sure they make sure that 7 minutes in the oven won't hurt anything. I know a number of people who have baked lights during retrofits, never an issue.

I'm more concerned about the new acrylic lens deforming. But you raise a good point!

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The lens would be a concern. If I remember correctly that was only heated to about 150 right?

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350, so I guess it should be fine. I'll try it and find out. Worst case, I buy another piece of acrylic, make a new one and try again

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343a224336fd2db01c82cb646dfe5ab6.jpg

 

 

separated at birth??

 

 

 

 

walli.jpg

 

 

 

 

Joking aside, that is some skill/ingenious you display here! well done!

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Joking aside, that is some skill/ingenious you display here! well done!


Thanks Dutchy. Means a bunch coming from somebody with your reputation on this board!

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Can I ask if you used a vacuum former or just heat and let it form under it's own weight ?

 

Looks good by the way.

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Can I ask if you used a vacuum former or just heat and let it form under it's own weight ?
 
Looks good by the way.

I put it in the oven at 350° F for a little under 10 minutes. It mostly formed with it's own weight. I used the female piece cutout of the MDF to finish pressing down and a Dremel to cut off the excess. While the plaster and Bondo mold is still in the acrylic, I used a blowtorch to careful heat up the center of the lens and pressed down with the a large screwdriver to fill in that portion.

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