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Fog Light Conversion to Projector

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Old Feb 25, 2006 | 03:25 PM
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Redspark
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Joined: Jun 2004
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From: Bethel Park Pa
Default Fog Light Conversion to Projector

I f you have a fat wallet buy the PIAA's 1100x and read no further. If you are a klutz and lack patience this project will have you cursing. But for everyone in-between this is worth considering. I gutted the existing fog light fixture and installed a 50 watt M16 projector bulb. The bulbs cost $5.98 at Advance Auto Parts . Because it uses the existing fixture it can be precisely aimed. The new bulbs outperform the low beam headlights. I do not want to argue LOW BEAM CUTOFF or HEADLIGHT HEIGHT. You decide .
First look over all the pictures on the following web site. I will not cover 100% of the details. You will have to do some problem solving. Do not start job unless you have a magnetic and claw part retriever.

http://users.adelphia.net/~rmamajek/index.html

I tested the new bulb to see if it was suitable. I operated it for 30 minutes and then poured water on it. I was wearing a full face shield since I expected it to explode or at least crack. It just gave off steam and kept working. The bulb comes with its own lens cover and reflector.

To remove the fog light fixture: Hand crank the headlight up. Remove the plastic around headlight. You now can reach down with one arm and remove electrical connector on back of fog light. Locate single 10mm bolt holding fixture ( you can’t see it you have to feel it). Use ¼” ratchet, 2” extension and 10mm socket to remove bolt HALF WAY. Now use fingers to finish removing bolt and it you are clever you will retrieve the bolt and fixture with out dropping either using only one hand in the blind.
To gut fixture: Cut adhesive on front lens ring, on any parting line with razor. All glue separations take time and patience ( 5 to 30 minutes per step). Apply pressure with knife or screwdriver until ring releases. Do not ask me how to fix a broken ring, which is not an option.
Remove bulb and insert rod in bulb hole to push out lens. It takes a lot of force and time. Then remove low beam cutoff (small piece of sheetmetal). Now cut off reflector on back of fixture. My reflectors were bad. They were burnt and corroded. I did not regret destroying them.

Now comes the hard part. I suggest you make an 18” electrical wire lead for the light. You can buy the socket( GX5.3) or improvise. Use high temp wire. YOU figure out how to connect the wire to the bulb and to the existing power connector ( remember it is down at the bottom of the hole that you can’t see).I did it using 12” long nose pliers and forceps like a surgeon.
Also you will have to remove the fixture to replace the bulb ( that is why I want 18” of wire so that I do not have to fight the wiring battle again).

To remount fixture: Everything should be wired before installing fixture. Now with one hand you will find the mounting bolt hole ( in the blind) and remount fixture. First starting the bolt finger tight, then tighten with ratchet. Make sure light is centered in plastic surround before final tightening or you won’t find the aiming screw behind the aiming hole!
Replace headlight plastic and aim new lights. See CF thread on aiming. Now you get to do it all over again on the other side.
Now I see the light! (Picture Blues Brothers)

Coming Soon ________10 minute C5 Side Screen Installation!
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