Projector Headlight Conversion

The headlight i modified by myself.
It is a bixenon lens not led. These are NHK bixenon projectors "mini H1".
tried to install in the low beam reflector but it didn't fit so I installed it in the high beam area.
Works as low and hi beam together and gives an excellent light pattern. Wished to add the second lens which would have given a higher intensity and better light but as I said the front cover wouldn't close tightly.
The best part that fixing the projectors doesn't need any drilling in the reflector so they can be easily uninstalled. Just a big screw from the back where you install the bulb.
will try to upload some images.

Thanks for the photos Ahmed. This looks to be a very interesting mod. Did you have to separate the light housing to install that light? If so how did you separate it? Do you have a link to the source for the “mini H-1” projector? And most importantly; once all is assembled is the light adjustable?

I needed to open the headlight (removing the front bezel from the housing) to be able to insert the projector from the front, and then tie the big screw from the back where the base of the bulb sits. separating the bezel from the housing is very simple. i warmed up the oven and once it reached high temp I switched it off then insert the headlamp for 1 min. once you get it out with a pryer you start prying to be able to separate these two.
Yes the light is adjustable as the projector is fixed to the original reflector, the screws for adjusting the light work normally moving the reflector as needed.
I tried to add links for the projector online but I can't post any external links.
I bought these from Egypt as they are available locally but you could find them easily on ebay and amazon by searching for mini h1 bixenon. I believe there are later technologies using LEDs which are available also from NHK and projectors are much smaller.
Also you could search for mini h1 under the brand "Morimoto".
it is 2.5 inch projector with H1 bulb.

Am I correct in assuming that the base of the NHK light assembly fit into and thru the hole where the OEM high beam bulb fits, and then it is firmly attached with the hardware as shown in the first picture?

If so does the NHK firmly seat in the reflector? It would seem to me that if there were any wiggle room in seating the NHK to the reflector that the bulb aim could be askew with no way to adjust the aim without compromising the aim of the low beam.

Cosmic_Jumper wrote:

Am I correct in assuming that the base of the NHK light assembly fit into and thru the hole where the OEM high beam bulb fits, and then it is firmly attached with the hardware as shown in the first picture?

If so does the NHK firmly seat in the reflector? It would seem to me that if there were any wiggle room in seating the NHK to the reflector that the bulb aim could be askew with no way to adjust the aim without compromising the aim of the low beam.

Yes exactly it is firmly attached through the bulb base and you add the plate for the H7 to fix it from the base of the bulb. The most interesting part is that they include a rubber holder that is fixed between the projector and the reflector, tightening the back screw squeezes this rubber and this prevents any vibrations during driving thus preventing any free play in the lens. I have this for over 6 months now and i am extremely happy with the lights and thinking of re-modifying the headlight to include another smaller LED projector in the low beam reflector to give a more agressive look and brighter light for the low beam.
I have attached an image to show the rubber part.

Ahmed, this looks like a clean, significant improvement over the OEM headlight lighting system. You've certainly caught my attention. Congratulations!

If you proceed with the low beam conversion project, it would be awesome if you took pictures of each step of the process and posted up a bit of a "how to" tutorial. I for one, would be very interested and I suspect others would be too. Thanks for sharing.

Heat?

sonuvabug wrote:

Ahmed, this looks like a clean, significant improvement over the OEM headlight lighting system.  You've certainly caught my attention.  Congratulations!

If you proceed with the low beam conversion project, it would be awesome if you took pictures of each step of the process and posted up a bit of a "how to" tutorial.  I for one, would be very interested and I suspect others would be too.  Thanks for sharing.  

Thanks a lot Sonuvabug, sure I will take pictures of each step to describe the whole process from A to Z.
I am glad you liked the modification.

john grinsel wrote:

Heat?

Ofcourse there is heat from the xenon bulb but I didn't meet any problems with this so far.
Already the halogen bulb generates heat, the difference is that when you operate the high and low beams in the stock setup you have heat created from 2 bulbs which I believe will be more than 1 xenon bulb.
if you are concerned with the heat generated from the xenon bulb you could either use an LED projector otr just use an LED bulb that is compatible with the projector.