Projector lighting into Sedan Headlights

[CustomMSP]

I know that there are plenty of how-tos on this subject, but I haven't seen any for the Sedan Protege with a mounting system I've devised. I think that my system is much stronger with better weight distribution for long term durability, as well as much easier projector alignment.

I'd originally installed my G35/FX35 projectors into Protege5 headlights, as they have separated low and high reflectors offering a cleaner look, in my opinion, without the use of any shrouds. I had the low beam reflected and the projector painted black, disguising the "guts". However, the mounting system I used wasn't that clean and secure. The projectors were just held on to the reflector by 4 screws through the rear, causing the reflector to crack around the screw holes over time.

The nice thing about Sedan headlights is that the reflector is much larger, offering more mounting options and better weight distribution of the heavy projectors. You have to remember that these reflector mounts were not designed to hold a lot of weight, only that of the bulb and the reflector. Another nice thing about the Sedan reflector is that the G35/FX35 projector's rear housing fits nicely into the bulb opening of the reflector with a slight notch at the top of the reflector bulb mount as can be seen in the attached images.

Anyway, take a look at the attached images to see what I'm talking about here. Please comment and / or make suggestions for improvements! I'll post more pictures as I progress.

Thanks.

 

[IshSonP5]

so with the G35/FX35 projector's the only cutting you had to do was that single notch??

 

[CustomMSP]

Yep!

Here's a picture of the P5 reflector, modified to accomodate the G35/FX35 projector, compared to the Sedan reflector.

 

[CustomMSP]

Finished light (as of now). Still need to test the alignment of the projects, but otherwise I think that I'm done with it.

 

[IshSonP5]

Nice. The P5 headlight compared to the sedan light is almost ridiculous what it took. I will definitely look into these projectors with the sedan light. Thanks for the info!

 

[njaremka]

you might end up with a rotation misalignment. that flat part of the sedan lights is not level with the ground. i hope you figured that out before you sealed the lights back up.

 

[CustomMSP]

you might end up with a rotation misalignment. that flat part of the sedan lights is not level with the ground. i hope you figured that out before you sealed the lights back up.

You bring up a good point. I had this issue with the P5 lights. This time I'd spaced out the projectors on the inside by about 1/4 in.

 

[AzteCypher]

How visible are those stands that hold the projector up when viewing the headlight from the front?

 

[CustomMSP]

Somewhat. A few options are to paint it all black, get a different shroud or to use some other brackets. That's all that I could find that'd work without having the need for power tools to be able to modify other ones.

 

[CustomMSP]

Finished lights output;

 

[njaremka]

nice job

 

[CustomMSP]

Thanks, man. I'm really happy with the way this came out this time around.

Some pics of the finished product on the car;

 

[AzteCypher]

How do you adjust the beam?

 

[CustomMSP]

The X and the Y adjustments are done with the headlight's built in adjustments, as long as the projectors are mounted more facing the center of the car like so /\ inside of the reflector. Otherwise there won't be enough adjustment in the built in headlight X adjustment and the beam will end up too far apart from each headlight. The rotation has to be set permanently before sealing up the lights. In my case, I had to space out the inside mounting bracket by about a 1/4 in. on the bottom.