LS1TECH - View Single Post - Bi-xenon projector Retrofit on my 95 TA, with pics

MOE_TAWS6 · 02-19-2009, 01:05 AM

First off, this is not the easiest thing to do. It wasn't really that hard, but a bit time consuming. If you do not have patience, do not try this at home! lol

I got it from here...
93-97 Firebird Bi-Xenon FX Projector Retro-fit ***UPDATED W/ WRITE-UP***

Started off with Headlights out of a 2008 BMW 5-series. I got a great deal on these. Otherwise, you can buy a set of bi-xenon projectors on ebay for about $125ish. I DO NOT recommend these considering they require you to cut out the back of your headlight assembly/and part of the radiator support. (Can't be seen, but still more work than you want to do). Blackbirdws6 used fx projectors which are shorter in length, and did not require him to cut anything out from behind.

Then i had to tear it all apart, and get the good stuff from inside.

After doing one headlight....The good in one box, the bad in the other.

So i took both all apart.

(No pics on this part)Next I Cracked open a stock headlamp. Filled the backside up with plaster, and let it dry. After it dried, i took it out, and sanded it down until it was smooth, and mostly even.

After that, i took some plexiglass, I bought 2 sheets, each 8x10, .80 acrylic.
Heated the oven to about 300, let it pre-heat. I grabbed a few paint stirring stick from lowes, and used those as a border for the plexiglass. I used big metal paper clamp/clips to hold the wood to the plastic.

I grabbed a 3" deep baking pan, and set the plexiglass/attached to the wooden frame, on the pan. (It sat on the borders of the pan) It being deep, allows room for the glass to go down when it starts to sag from the heat. I tossed it in the oven for about 5-6 minutes. After that, you take it out, fast, and wearing thick gloves, you place it over the mold that you made. Then you quickly take the headlight bezel/trim and force it down on the plexiglass around the mold. This allows the edges of the bezel to line up with the plexi. This does take trial and error. I went through about 5 of these sheets, and even the last ones i made, aren't perfect. This was my weakest part in doing all of this.

After you are satisfied with a set that you made, you can then cut them out, and use RTV to seal them up with the headlight trim pieces. (I wasn't satisfied, but got a hold of more Headlight Trim pieces, so i can make more later, and change these out when I have time to make them perfect) 1983 Chevy Caprice's use the same bezels!

Next, you take LEXAN glass, and cut a circle in the middle, almost the diameter of the projector. (With the metal, not just the glass)

Then i had to cut/trim the Shrouds i had, because they were too big.

I may have done this part differently than blackbirdws6, but its similar. I cut the Lexan glass, so it would fit nicely inside the factory black headlight box thing. After cleaning the projectors, i placed the lexan glass around them, and RTV'd them into the headlight box, to give them a nice seal around the front. I then, placed the shrouds around the projectors, and rtv'd them there. (Carefully)

My old headlamps are in the middle.

And that is as far as I have gotten so far. Within the next few days hopefully, or maybe this weekend, I will cut out part of the radiator support, and post pictures of how they look.

The only thing I am not satisfied with is the covers. I am going to Redo them whenever i have time, and swap them out.

If you have trouble understanding any of this, you can look here, and it might be explained differently.

93-97 Firebird Bi-Xenon FX Projector Retro-fit ***UPDATED W/ WRITE-UP***

02-19-2009, 01:05 AM	#1
MOE_TAWS6 12 Second Club Trader Rating: 14 Join Date: Jun 2005 Location: Charlotte, NC Posts: 358	Bi-xenon projector Retrofit on my 95 TA, with pics First off, this is not the easiest thing to do. It wasn't really that hard, but a bit time consuming. If you do not have patience, do not try this at home! lol I got it from here... 93-97 Firebird Bi-Xenon FX Projector Retro-fit *UPDATED W/ WRITE-UP* Started off with Headlights out of a 2008 BMW 5-series. I got a great deal on these. Otherwise, you can buy a set of bi-xenon projectors on ebay for about $125ish. I DO NOT recommend these considering they require you to cut out the back of your headlight assembly/and part of the radiator support. (Can't be seen, but still more work than you want to do). Blackbirdws6 used fx projectors which are shorter in length, and did not require him to cut anything out from behind. Then i had to tear it all apart, and get the good stuff from inside. After doing one headlight....The good in one box, the bad in the other. So i took both all apart. (No pics on this part)Next I Cracked open a stock headlamp. Filled the backside up with plaster, and let it dry. After it dried, i took it out, and sanded it down until it was smooth, and mostly even. After that, i took some plexiglass, I bought 2 sheets, each 8x10, .80 acrylic. Heated the oven to about 300, let it pre-heat. I grabbed a few paint stirring stick from lowes, and used those as a border for the plexiglass. I used big metal paper clamp/clips to hold the wood to the plastic. I grabbed a 3" deep baking pan, and set the plexiglass/attached to the wooden frame, on the pan. (It sat on the borders of the pan) It being deep, allows room for the glass to go down when it starts to sag from the heat. I tossed it in the oven for about 5-6 minutes. After that, you take it out, fast, and wearing thick gloves, you place it over the mold that you made. Then you quickly take the headlight bezel/trim and force it down on the plexiglass around the mold. This allows the edges of the bezel to line up with the plexi. This does take trial and error. I went through about 5 of these sheets, and even the last ones i made, aren't perfect. This was my weakest part in doing all of this. After you are satisfied with a set that you made, you can then cut them out, and use RTV to seal them up with the headlight trim pieces. (I wasn't satisfied, but got a hold of more Headlight Trim pieces, so i can make more later, and change these out when I have time to make them perfect) 1983 Chevy Caprice's use the same bezels! Next, you take LEXAN glass, and cut a circle in the middle, almost the diameter of the projector. (With the metal, not just the glass) Then i had to cut/trim the Shrouds i had, because they were too big. I may have done this part differently than blackbirdws6, but its similar. I cut the Lexan glass, so it would fit nicely inside the factory black headlight box thing. After cleaning the projectors, i placed the lexan glass around them, and RTV'd them into the headlight box, to give them a nice seal around the front. I then, placed the shrouds around the projectors, and rtv'd them there. (Carefully) My old headlamps are in the middle. And that is as far as I have gotten so far. Within the next few days hopefully, or maybe this weekend, I will cut out part of the radiator support, and post pictures of how they look. The only thing I am not satisfied with is the covers. I am going to Redo them whenever i have time, and swap them out. If you have trouble understanding any of this, you can look here, and it might be explained differently. 93-97 Firebird Bi-Xenon FX Projector Retro-fit *UPDATED W/ WRITE-UP* __________________ 348 rwhp / 355 tq 355c.i, LT4 Hotcam, 1.6 RR's, Caddy Race lifters, Jet Hot LT's, Borla Exhaust, 4.10's with T/A girdle, Edlebrock Adjustable Torque Arm, J&M relo brackets, J&M SFC's, Hotchkis LCA's, J&M adjustable PHB, Strano springs, Koni DA-fronts/SA-rears, 19x9.5 Axis Hiro's For now...E/T 12.81 at 111.4 mph will have to do. Last edited by MOE_TAWS6; 02-19-2009 at 02:41 AM..