Whats up guys, I have been working on this for a while now, I figured I have enough progress to start one of these threads. Anyways...heres the specs

-05-07 spare headlights to be torn down
-Nissan murano bi-xenon projectors
-STI-replica clear lenses
-E46 replica shrouds
-Matsushita ballasts & ignitors
-Phillips 85122+ 4300k bulbs

Onto the pics:

First, I started by playing with the new lenses and getting the spacing right to get the right amount of color and sharpness at the cutoff...

Ouput of Murano with regular lense:


Output of Murano with STI-replica clear lense:




Then, took the first light apart and started cuttingit up to fit the projector...

Un-trimmed murano projector and headlight, these puppies are HUGE!:


I then trimmed the tabs off of the projector and trimmed the reflector to allow the projector to fit. This is the intial test fit.




Drilled holes in the reflector to mount the projector on. Here is the initial mockup of this:


And with the shroud on:


At this point, the projector was sitting just a little bit too high for my liking. I did some more trimming and re-drilled the mounting holes to lower it a tad.



Then, I started painting the headlight...
Sanded chrome finish off:


Primered:




Then finished painting and wetsanding it, cleared it, and put it back together. Here are the pics of it on the car and getting the alignment fine-tuned before locking everything into place with jbweld:






Beam pattern:


And vs. stock:




Next, I needed to come up with a way to seal the headlight behind the projector, but still have access to it incase a bulb dies. Here is what I came up with after a trip to lowes. I still need to finish sealing up everything and probably paint it to make it not so ugly.




With the cap off:


The bi-xenon shield and ignitor wires coming out of the side of the headlight (need to seal)


I then cleaned everything real well and re-installed the lense....

"Finished" (so close) pics:





I just got started on the other light last night. Hopefully I'll get it finished in the next week or two.

BTW, one of my headlights i got off of ebay was a TYC aftermarket light. Just a word of warning, these aftermarket lights are a BITCH to get taken apart. Also, I couldn't get the reflector pulled off of the mounting tabs. (even after shooting the plastic tabs with a heat gun long enough to make the plastic start to sweat) I'll have to do this other light with the reflector mounted in place. It shouldn't be too hard, just cutting it will be a pain.

 

Sweet!

Nice work, everything is coming along very nicely.

 

Thanks!

And sorry about the low-quality pics. I am doing the majority of the work in my basement and the lighting is horrible.

 

all i can say is wow. making me want some retro's this summer. I am not likng the projectors!

 

nicely done brett

 

awsome work man


where did you get those shrouds?

 

theretrofitsource.com or theretrofitsource on ebay, same place I got the lenses. Just do an ebay search for e46 repica shrouds and you'll find 'em. They come in 3" or 2.5" inner diameter to fit whichever size projector you have.

 

ok thanks

 

Wow they came out real nice..prefect cutoff too and no hot spots like the eBay projectors! Grate job