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Pre Kat Projector Retrofit

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  • #1

    Pre Kat Projector Retrofit

    Working on some ideas for retrofitting two projectors into a pre katana. I have some projectors and housings lying around so I'm trying to think the of the best possible solution to this.
    So far, the ideas are:

    Projectors


    Projectors behind the halogen glass. Outcome: Still would look moderately stock, not sure how crappy the output pattern would be behind the oem lens.

    Or, I could wrap the oem bulb in syran wrap or such and fiberglass to the same shape, then mount plexiglass or such into it.


    Or, do the fz600 dual-round headlight mod and replace the 5.25" round headlights with clear headlights (GMC Envoy foglights are 5.25" also and clear lens) and then retrofit the projectors into those housings.


    (Envoy housing)


    Aftermarket Envoy projector fogs


    So far these are the only ideas. I'm very interested in any other opinions and would really appreciate them. Thanks
    Last edited by Lykkan; 02-06-2012, 05:34 PM.

    Built up Black 94 5.0 Mustang - Champagne Pearl 2001 Chrysler LHS - Canary Yellow 2001 Katana 600 - 94 F350 7.3 IDI turbo crew cab dually
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  • #2
    I'm working off and on (more off than on lately) on the same thing. You can fit two 2.5" projectors inside the shell just barely (I think). I'm planning to cut a plate to attach to the front of the stock reflector and cut up the reflector to make room for the projectors. I'm not sure yet if I'll have to do something to the shell to allow access to the bulbs or if I'll be able to fish them in through the existing hole in the back.

    As for the high/low beam thing, I've got D2S bixenon projectors so the switching is done at the bar, through the stock harness without having to mess with diodes. Power to the ballast is through a relay, directly from an aux fuse panel I installed.
    Wherever you go... There you are!

    17 Inch Wheel Conversion
    HID Projector Retrofit

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    • #3
      from what ive seen and heard the projectors would work terribale behind the stock lense because of the reflectos in it. i would go with either the round headlights or try replacing the reflectors if posibble. or get a custom made lense/housing lol

      Originally posted by Wild-Bill View Post
      I'm working off and on (more off than on lately) on the same thing. You can fit two 2.5" projectors inside the shell just barely (I think). I'm planning to cut a plate to attach to the front of the stock reflector and cut up the reflector to make room for the projectors. I'm not sure yet if I'll have to do something to the shell to allow access to the bulbs or if I'll be able to fish them in through the existing hole in the back.

      As for the high/low beam thing, I've got D2S bixenon projectors so the switching is done at the bar, through the stock harness without having to mess with diodes. Power to the ballast is through a relay, directly from an aux fuse panel I installed.
      let us know how it turns out wildbill id liketo put better lighting in mine also
      Last edited by boomer_95; 02-06-2012, 05:43 PM. Reason: Automerged Doublepost
      if all else fails......... Get a hammer

      parting out my 89 Kat 750

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      • #4
        You're not using the reflector except to hold the projector. I already did a single projector retrofit and it turned out pretty well. That's why I haven't been in any great hurry to get the dual projector mod done.

        On the single projector retrofit I used metal duct tape to block the light leakage on the sides of the projector. Others have painted the reflector to avoid any reflection from it. I would have done that except I wanted to keep things looking close to stock when the light is off. The dual fit will probably have the adapter plate painted a non-reflective silver.
        Wherever you go... There you are!

        17 Inch Wheel Conversion
        HID Projector Retrofit

        Comment

        • #5
          Originally posted by boomer_95 View Post
          from what ive seen and heard the projectors would work terribale behind the stock lense because of the reflectos in it.
          He's putting projectors in, there will be no light hitting the relectors at all...
          90% of motorcycle forum members do not have a service manual for their bike.

          Originally posted by Badfaerie
          I love how the most ignorant people I have met are the ones that fling the word "ignorant" around like it's an insult, or poo. Maybe they think it means poo
          Originally posted by soulless kaos
          but personaly I dont see a point in a 1000 you can get the same power from a properly tuned 600 with less weight and better handeling.

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          • #6
            I think he's refering to the prism in the lens it's self.
            "I'm sorry, I didn't mean to upset you when I called you stupid. I thought you already knew..."
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            • #7
              Based on my single-projector install, there's very little if any effect from that.
              Wherever you go... There you are!

              17 Inch Wheel Conversion
              HID Projector Retrofit

              Comment

              • #8
                After seeing Wild-Bill's projector light pattern, I enjoyed the idea of using the original housing.

                Stock housing


                Drilling holes to fit the bodies of the projectors





                The body rests snuggly into the holes that were made, going to use a headless bolt between the two of them, then drill a hole in the chrome housing on each side to bolt into the oem holes on the projectors. Will get more updates when I find the bolts I need.
                Inside of the headlight is going to be flat black except the projectors will still have the aluminum ring around them. One will be the low beam (that will always be on, even with highs on) and the other will be the high beam (projectors will both be aimed the same, but the bulb on the low-side will have a spacer put in to move the HID bulb back farther so it has a lower cut-off line)
                Thanks Wild-Bill for the concept
                Last edited by Lykkan; 02-26-2012, 06:33 PM.

                Built up Black 94 5.0 Mustang - Champagne Pearl 2001 Chrysler LHS - Canary Yellow 2001 Katana 600 - 94 F350 7.3 IDI turbo crew cab dually

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                • #9
                  Originally posted by 92xjunker View Post
                  I think he's refering to the prism in the lens it's self.
                  Sorry i was actually thinking of HID's not projectors. but it looks great! keep us posted. what projectors did you end up going with tho? (for future reference) the envoy's?
                  if all else fails......... Get a hammer

                  parting out my 89 Kat 750

                  Comment

                  • #10
                    You don't have bi-xenon projectors with the shutters for high/low beam?

                    I'm wondering how you're going to finagle the two separate aim points. With the bi-xenon projectors you can set them both in the reflector aiming at the same level and then use the original adjusters to get the low beam cutoff right. With the setup you're talking about it sounds like you're going to have to pet the aim on the two projectors relative to each other plus play with the low beam adjustment.

                    Probably a bit late if you've already got money invested in the projectors but the other advantage to using bi-xenons is that the bulb doesn't cycle on and off as you switch from high to low beam and back again. You just cycle a solenoid which moves the shutter.
                    Wherever you go... There you are!

                    17 Inch Wheel Conversion
                    HID Projector Retrofit

                    Comment

                    • #11
                      Originally posted by Wild-Bill View Post
                      You don't have bi-xenon projectors with the shutters for high/low beam?

                      I'm wondering how you're going to finagle the two separate aim points. With the bi-xenon projectors you can set them both in the reflector aiming at the same level and then use the original adjusters to get the low beam cutoff right. With the setup you're talking about it sounds like you're going to have to pet the aim on the two projectors relative to each other plus play with the low beam adjustment.

                      Probably a bit late if you've already got money invested in the projectors but the other advantage to using bi-xenons is that the bulb doesn't cycle on and off as you switch from high to low beam and back again. You just cycle a solenoid which moves the shutter.
                      Thanks, I was trying to remember the name of those HID's. I'm not 100% sure if they have bi-xenon's for H3 bulbs but I'll look into it. So far I have $2.42 into this project since I already had the projectors sitting around from when I put one of my chrysler's into a ditch during thick fog. Replaced them and kept the old projectors, which I'm using for this project.

                      And the low-beam would always be on, so there wouldn't be any moment without light anyways. I'll look into the bixenon's and get back with the thread, Thanks

                      Built up Black 94 5.0 Mustang - Champagne Pearl 2001 Chrysler LHS - Canary Yellow 2001 Katana 600 - 94 F350 7.3 IDI turbo crew cab dually

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                      • #12

                        still need to drill holes on the outside of the metal housing and put bolts in, should be good. Didn't have to modify anything to the plastic housing, so it'll seal off the same way it did before.

                        Built up Black 94 5.0 Mustang - Champagne Pearl 2001 Chrysler LHS - Canary Yellow 2001 Katana 600 - 94 F350 7.3 IDI turbo crew cab dually

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                        • #13
                          Definitely post up some pics when you get them installed and working! I wanna see this.

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                          • #14
                            It's not the whole light setup that's going to cycle on and off, it's the high beam bulb. It takes a couple of seconds to cycle fully on which means you don't get your high beam instantly when you flip the switch and then there's also the matter of wearing out the bulb. On/off cycles have more to do with life of the bulb than time on.

                            Do those projectors have a couple of small wires hanging out the back that don't go to the bulb? I don't see a shutter through those lenses but I'm hoping.
                            Wherever you go... There you are!

                            17 Inch Wheel Conversion
                            HID Projector Retrofit

                            Comment

                            • #15
                              Originally posted by Wild-Bill View Post
                              It's not the whole light setup that's going to cycle on and off, it's the high beam bulb. It takes a couple of seconds to cycle fully on which means you don't get your high beam instantly when you flip the switch and then there's also the matter of wearing out the bulb. On/off cycles have more to do with life of the bulb than time on.

                              Do those projectors have a couple of small wires hanging out the back that don't go to the bulb? I don't see a shutter through those lenses but I'm hoping.
                              Right, my fogs and low beams are HID on my one chrysler, then the highs are halogen but I don't really even use them because the fogs are so bright (I keep them off in town) and those are the same projectors that are going into this project
                              shutter?
                              like a piece of metal for a cutoff line? it has that

                              Built up Black 94 5.0 Mustang - Champagne Pearl 2001 Chrysler LHS - Canary Yellow 2001 Katana 600 - 94 F350 7.3 IDI turbo crew cab dually

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