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Projector & Bi-Xenon retrofit... in progress.(more pics!)

6.1K views 44 replies 18 participants last post by  moe  
#1 ·
The quest for brighter light & the gain of free parts from broken cars at work has brought me here today. So I acquired a full hid set up from a car at work, SCORE! Bi-xenon projector, bulb, ballast, and igniter. Now I've searched and so far found nothing about putting a projector in the ex five hundo(correct me if i'm wrong). So hopefully anyone that wants to do this may find this helpful. I apologize in advance for the sloppy cell phone pics, my real camera has recently gone blind...

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I have the projector out of an E class Benz... not too user friendly. Most other bikers who have done this use tsx, infinity, or audi projectors. Mainly because they are smaller, cheap, and the lens part comes off to make a real easy trace for a mounting template. But I have what I have, free... so here I go haha.

Here's my original hacked up template.
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Notice I have the stock plastic(white pieces) mounting inserts for proper aiming.

Here's my latest template
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The reason that there is a cut out in the bottom is one, because of the high beam shutter solenoid & two, because the projector needs to sit pretty low to clear a certain metal cross member on the front fairing frame.
And that's where I'm at, been using a cut off wheel prior to my latest template in which I'll need a jig saw for(to get a more precise & cleaner cut) but don't have at the moment. I plan to use power and ground to my igniter module from the stock headlamp connector and rigging up a switch on a seperate circuit for the high beam shutter somewhere. I tested it and our bikes take power away from the low beam circuit when switched to high beam so that would kill my bulb but the shutter would move lol.

Not sure what I'm going to do for a lens as the stock one has a very distinct scatter pattern for the halogens... maybe some type of Plexiglas retrofit or a perfectly clear lens if it exists! Please ask questions if you have them I'm sure there are holes in my story lol and I will definitely keep you guys up to date!
 
#2 ·
Re: Projector & Bi-Xenon retrofit... in progress.

This looks really awesome, keep us up to date man. I'm digging what you're doing and HOW you're doing it.

you really cant argue with the word FREE for parts.
 
#3 ·
Re: Projector & Bi-Xenon retrofit... in progress.

Thanks! ;D
I can't take all the credit I did get the metal mounting pate idea from a f6z post i saw on sportbikes.net forum.
 
#4 ·
...lights on

Quick pic update, no where near done. I still have to figure out a lens and how to seal the back... I got a little cut happy early on :(
Final template
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Control module mounted
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Fairing up
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Light on
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The bike is still in my apartment while I finish up and it's only like a foot away from the wall so that really doesn't do the light justice.
Lemme know what ya think!
 
G
#5 ·
Honestly, looks kind of like a futuristic robot like that... which is kinda cool but doesn't look too well. I think to really pull this off slickly would require buying the racing fairing from Airtech and cutting out your own headlight hole!
 
#7 ·
yeah still stewing some ideas around for a lens... but I also like the look of the chrome bezel, there's not really any chrome floating around up front like there is in the back(pipes), so why not add some?
 
G
#10 ·
I'll tell you what. It wouldn't look bad at all if you filled in the empty spaces between the square headlight housing and the fairing, and then put shaped plexiglass across the whole thing. I don't know if that's realistic to shape plexiglass though, I'm kind of talking out of my butt here.
 
G
#11 ·
Pogo said:
I'll tell you what. It wouldn't look bad at all if you filled in the empty spaces between the square headlight housing and the fairing, and then put shaped plexiglass across the whole thing. I don't know if that's realistic to shape plexiglass though, I'm kind of talking out of my butt here.
+1 on this, especially if you could find an old reflector to cut up to fill the empty space with... have you considered taking the stock headlight and cutting a round hole in it to mount the projector? I've seen other sport bike guys do that but frankly don't even know what the ex headlight looks like as mine has the airtech fairing.
 
#12 ·
I wonder if plexiglass will melt. I dont know how hot hids get exactly. But that aside yes you can bend the plexiglass onto the stock lens shape. Like you can curve it using a heat gun. As far as the back goes. If you ask me, use a metal bucket on the back and then make the inside of it with fiberglass to round it off and make it look smooth instead of metal corners everywhere.
 
#14 ·
Looking good, man. I'd say chop up a stock headlight, cut a hole in the front for the projector to fit through, and fill the edges and paint it to match the rest of the fairing, so all you see is a frenched projector, no other hole/plate/etc at all.
 
#17 ·
I'm thinking get a number plate from racetech, and cut out a hole for the projector, put a gasket in between the plate and projector to waterproof it, bam. done.
 
#18 ·
i personally dont like the round eye. It looks different but it looks too different in my opinion since the ninja front is way too flat. It looks like something is missing
 
#21 ·
Well my roomy convinced me to just put the stock glass back on for now so we can ride to work and such.
I really didn't wanna do this cause it'll kill the cut off of the HID projector and some of the effect of it too.
Buttttttttttttttt.......... I did it and now I'm trying to figure out what else I can do, bought a used headlight, maybe I'll mock something up with that. Maybe I will pick up a fairing too since I do have the ole sidemarker punch out damage...
 
#22 ·
Anyone ever try these lights on the bike? They are Xenon but do not require the kit. I got them for my car 4 or 5 years ago and they are bright and seem to work great. I did notice that sometimes the super white i got gets lost in the city - is there a color that might work better? When I compared them against a wall to other cars they are way brighter. If am outside the city on high beam they light up the road very well. I can not seem to find the color choices on the site anymore but maybe I am missing it.

http://xenonlightshid.com/
 
#24 ·
Well, to be more accurate, they are Xenon gas filled tungsten filament lamps. There is no Halogen in them.

HID is a high voltage electric arc that spans a gap filled with Xenon and mercury gas. when it gaps, it turns the mixture into a plasma, which emmits an incredibly intense light. the equvilent of a replacing your 55w lamp with a 400W lamp. they are that much brighter. I forget the lumen output, somewhere in the 1200's...
 
#26 ·
Well i decided to go with the fatboy bulbs after all. They are normal bulbs so they wont need a hid reflector.

I present u IPF Fatboy II

Stock H4 (left headlight)
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IPF Fatboy II (right headlight)
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stock vs fatboy together
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