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Thread: 2.5" Projector with bi-xenon lights

  1. #1

    2.5" Projector with bi-xenon lights

    I have always found the stock H4 incandescent bulbs a terrible lightning solution, it has no focus and lacks power. I've been wondering about bi-xenon for a while and got to put it together this weekend.

    About 5-6 hours of work from getting the headlights off the car to finished installation.

    I'm absolutely pleased with the results, the car not only looks better now but also improved visibility A LOT.

    I used 2.5" full metal version 9.5 projectors (https://a.aliexpress.com/_msIA1an), E46 extended shrouds, and CN light bulbs and ballast (https://a.aliexpress.com/_mN0dJU3).

    The lens removing process is quite straightforward: using the heat gun give it a fast heating all around the edges (try to focus heat on the black plastic) then choose a corner, heat that place better and start opening it by there. Don't forget to remove the screws and tabs. Closing it is pretty much the opposite job. There are several videos on YouTube regarding this part.

    H4 bulbs cuts power to low beams when high beams are turned on, that has to be worked around to use Xenon projectors, there are wiring harnesses available but I don't recommend them, they allow the ballast to turn off when returning from high to low beams, which causes a little flash, repeating this causes one of my ballasts to burn, after that I made my own harness .



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  2. #2
    Join Date
    Nov 2010
    Location
    Council Bluffs, IA USA
    Posts
    2,098
    Wow! Outstanding work and it's great to see other people taking the time to upgrade their SX4s still.

    I went a different route, I refinished the headlights with a 3M kit today into which I am installing Auxito LED lights. I'm sure they won't hold a candle to your projectors though, pun intended.
    '09 SX4 AWD 5-spd Technology Copper Sunlight Metallic - RIP
    '15 Ford Fiesta ST Tuxedo Black, Stage 2+ E30 tuned (SOLD)
    '09 SX4 AWD 5-spd Touring Copper Sunlight Metallic - v2.0

  3. #3
    How did your LED install work out?

  4. #4
    Quote Originally Posted by SmashedGlass View Post
    How did your LED install work out?
    I went for Xenon, haven't tried LED

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  5. #5
    Join Date
    May 2022
    Posts
    3
    Im a big fan of retrofits, I've done a handful of them myself usually using retrofitsource kits, from as far back as 2014.
    Is there a reason you opted for a 'frankenstein' kit rather than say the Acme line at TRS? I was actually looking to piece together a kit last weekend from Ebay/Amazon parts but by the time I found everything the savings in Canadian dollars wasn't much compared to just buying the Acme kit.

    The one piece that I was stuck on though (if DIY) was the harness. I was thinking of getting an H1 to H4 HID harness (easy to find), and cutting one plug from my SX4 and splicing on and H4 pigtail. So Im curious about how your DIY harness works and is made!

    Cheers

  6. #6
    Quote Originally Posted by klam07 View Post
    Im a big fan of retrofits, I've done a handful of them myself usually using retrofitsource kits, from as far back as 2014.
    Is there a reason you opted for a 'frankenstein' kit rather than say the Acme line at TRS? I was actually looking to piece together a kit last weekend from Ebay/Amazon parts but by the time I found everything the savings in Canadian dollars wasn't much compared to just buying the Acme kit.

    The one piece that I was stuck on though (if DIY) was the harness. I was thinking of getting an H1 to H4 HID harness (easy to find), and cutting one plug from my SX4 and splicing on and H4 pigtail. So Im curious about how your DIY harness works and is made!

    Cheers
    I really don't know that acme trs line, all I did was follow advice from a mate that works with retrofitting here in Brazil, he adviced me to get this projector and bulb brands and I did the rest.

    My own harness is pretty simple: the H4 socket in SX4 uses a common positive and switches negative for high or low, what I did was solder a diode between high and low, with the cathode pointing to the high beam terminal. Plug for ballast goes on common and low (diode anode), plug for solenoid goes on common and high. So when theres only low beam on, solenoid will be off, diode will not conduct and ballast will be power directly. On high beam, solenoid will be on, diodes will conduct and the ballast will be powered thought the diode. Picture attached, I used 2 diodes just so they can share the current and heat up less. Been using this harness for a bit more than an year now and haven't burned anything.

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  7. #7
    Quote Originally Posted by mateusleo View Post
    I really don't know that acme trs line, all I did was follow advice from a mate that works with retrofitting here in Brazil, he adviced me to get this projector and bulb brands and I did the rest.

    My own harness is pretty simple: the H4 socket in SX4 uses a common positive and switches negative for high or low, what I did was solder a diode between high and low, with the cathode pointing to the high beam terminal. Plug for ballast goes on common and low (diode anode), plug for solenoid goes on common and high. So when theres only low beam on, solenoid will be off, diode will not conduct and ballast will be power directly. On high beam, solenoid will be on, diodes will conduct and the ballast will be powered thought the diode. Picture attached, I used 2 diodes just so they can share the current and heat up less. Been using this harness for a bit more than an year now and haven't burned anything.

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    After some time I also 3d printed covers to hide the ballasts and make them look oem, they replace the oem rubber boots, sits very tight and has a oring to keep dust out http://cloud.tapatalk.com/s/63630e64...102-WA0031.mp4

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  8. #8
    Join Date
    Nov 2010
    Location
    Council Bluffs, IA USA
    Posts
    2,098
    Wow, awesome work!
    '09 SX4 AWD 5-spd Technology Copper Sunlight Metallic - RIP
    '15 Ford Fiesta ST Tuxedo Black, Stage 2+ E30 tuned (SOLD)
    '09 SX4 AWD 5-spd Touring Copper Sunlight Metallic - v2.0

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