Tahoe HID retrofit w/ Depo headlight & Lexus RX-AFS/TSX-R projectors...

Discussion in 'Tech Info' started by Physh1, Feb 11, 2011.

Car Parts
  1. Physh1

    Physh1 Full Access Member

    Posts:
    772
    Likes Received:
    19
    Joined:
    Jul 29, 2010
    Name:
    Cameron
    So here is my retrofit project...this is long...lots of pics...

    It was DenaiAK's retro write-up t that got me interested in a similar retro for 00-06 Tahoes...I didn't want an out-of-the-box solution. This projects ran me $500 for everything part wise. Besides the Depo headlights & the retrofit parts listed below I had to buy epoxy, silicone, & a piece of flat aluminum bar for fabbing the support brackets.

    I probably overbuilt them & it took about 14 hours to do the whole project over a few weeks. I did a little work here & there when I had time but most of the delays were because of epoxy curing & silicone curing.

    I started with Depo projector housings for 00-06 Tahoes & after looking around a little, asking some questions, & doing lots of Google searching I decided on a Lexus RX-AFS/TSX-R projector.

    Really, before I started this job, I only knew that the Depo projector headlights fit without modifying the supports or washer fluid reservoir & the Lexus RX-AFS/TSX-R projector were not quite a deep.

    Now...on with the pictures...

    ---------- Post added at 11:46 PM ---------- Previous post was at 11:44 PM ----------

    Got my HID retro parts from Matt @ retrofitsource.com...

    Phase I...basic projector prep & equipment info...

    Here is my collection of goodies...
    1x Pair: Lexus RX-AFS/TSX-R low beam projectors
    1x Pair: Clear optic lenses
    1x Pair: New Matsus h i ta Gen IV ballasts w/ brackets
    1x Pair: Morimoto 3Five 5000K D2S bulbs
    1x Pc: 9006 relay wire harness
    IMAG0454.jpg

    Close up shot of the opaque stock Lexus RX-AFS/TSX-R optics...
    IMAG0455.jpg

    Another shot of the stock optics...
    IMAG0456.jpg

    Stock optics removed...
    IMAG0457.jpg

    Clear optic lens sitting in the housing. This lens is slightly smaller in diameter & requires a compression ring to keep the lens centered & secure...
    IMAG0458.jpg

    Clear lens fully installed...
    IMAG0459.jpg

    Stock driver side Depo "donor" headlight front...
    IMAG0460.jpg

    Stock driver side Depo "donor" headlight back...
    IMAG0461.jpg

    Mounting bracket removed...
    IMAG0462.jpg

    The Depo projector is siliconed in place. I'll need to heat the area up with a heat gun to soften the silicone enough for safe removal. Once that is done I can start test fitting, trimming, & modding the housing to cleanly accept the Lexus RX-AFS/TSX-R low beam projector.
     
    Last edited: Feb 12, 2011
  2. Physh1

    Physh1 Full Access Member

    Posts:
    772
    Likes Received:
    19
    Joined:
    Jul 29, 2010
    Name:
    Cameron
    Phase II - Lexus Projector Install...passenger headlight...

    I did NOT bake these headlights to remove the headlight lens! I did all this work from the back of the headlight. You could bake them & make access to the shroud easier & gluing easier but I chose to proceed this way.

    So far I have 2.5 hours of work into this headlight...drying time not included.

    Here's the Depo housing after removing the projector...
    IMAG0471.jpg

    Depo projector on LEFT & Lexus RX-AFS/TSX-R projector on RIGHT...
    IMAG0465.jpg
    IMAG0464.jpg

    My collection of silicones & epoxy...
    IMAG0472.jpg

    The shroud in the Depo's is actually clipped onto the Depo projector so when I removed the Depo projector the shroud moved around. I used the epoxy to secure the shroud to the housing in 2 places. After I used a clear silicone fill the gaps & keep dust from getting in the housing.
    IMAG0474.jpg

    Here you can see a few spots I had to clearance with my Dremel to fit the Lexus RX-AFS/TSX-R projector...
    IMAG0475.jpg

    After a little fiddling, trimming, & lots of patience I got the Lexus RX-AFS/TSX-R projector centered in the shroud & stable. At this point I used the black silicone & used it on 5 spots to hold in in place. Once this dries & it's safer to handle I'll fill the rest of the gaps & do any final adjustments.
    IMAG0476.jpg
    IMAG0477.jpg
    IMAG0478.jpg

    After I let the silicone set for 3 hours I could handle it a little...
    IMAG0479.jpg
    IMAG0480.jpg

    Finishing filling in the gaps & gluing the projector in place...
    IMAG0484.jpg
    IMAG0485.jpg
    IMAG0486.jpg

    ---------- Post added at 11:50 PM ---------- Previous post was at 11:49 PM ----------

    Phase III - Bracket re-install...passenger headlight...

    Now with the Lexus projector installed & fully cured I need to trim the Depo mouting bracket so it will clear the Lexus projector. This basically meant installing & uninstalling multiple times for clearance & fit. I didn't want any part of the bracket any closer than 1/4"

    Here is the Depo mounting bracket on the housing & the arrow is pointing to the support I must trim to clear the projector...
    IMAG0487.jpg

    Closer shot of the clearance issue...
    IMAG0488.jpg

    Support bracket trimmed, cleared, & fully bolted back into place...
    IMAG0489.jpg
    IMAG0490.jpg

    5k bulb & ballast installed & connected. No clearance issues here...
    IMAG0491.jpg
    IMAG0492.jpg

    So far everything looks great. Next step will be adding a support leg to the support bracket I modified. Originally the support bracket was held in place by 4 screws (2 on the headlight housing & 2 on the Depo projector). Once a little support is fabbed this headlight is done & ready to be installed.

    Total time on retro on this headlight (minus drying time) is ~5 hours...
     
  3. Physh1

    Physh1 Full Access Member

    Posts:
    772
    Likes Received:
    19
    Joined:
    Jul 29, 2010
    Name:
    Cameron
    Phase IV - Fab up supports & mounting tabs...passenger headlight...

    Total time on retro on this headlight (minus drying time) is ~7 hours...

    2 supports fabbed & installed. White arrow support tab bolting projector to housing (2 screws). Pink arrow is support bracket to replace the original mounting bracket which I had to cut in order to fit the projector (one end bolted...one end epoxied)...
    IMAG0497.jpg

    Just another shot of the support tab & support bracket...
    IMAG0498.jpg

    This headlight is done, finished, completed, etc...
    IMAG0499.jpg

    ---------- Post added at 11:52 PM ---------- Previous post was at 11:51 PM ----------

    Phase V - Complete driver side build...

    Total time on retro on this headlight (minus drying time) is ~3 hours...got this one does a lot quicker now that I know what I'm doing :D

    No need to go over all the little stuff again. For the most part, the driver side build is the same EXCEPT for the needed trimming on the housing & the additional support...

    Here is the main spot for clearancing on the driver side headlight...it's the support post for the adjusting bracket...
    IMAG0522.jpg

    IMAG0523.jpg

    IMAG0524.jpg

    Bracket trimming & clearancing is basically the same on both headlights. Here are the two headlights...completed passenger above & almost completed driver below...
    IMAG0525.jpg

    Fabbing the new supports is different on the driver headlight. 2 supports...one for the adjusting bracket & one to support the projector...
    IMAG0526.jpg

    IMAG0528.jpg

    Both headlights completely done...
    IMAG0529.jpg
     
  4. Physh1

    Physh1 Full Access Member

    Posts:
    772
    Likes Received:
    19
    Joined:
    Jul 29, 2010
    Name:
    Cameron
    Phase VI - Installation :D...

    Ballast mounting worked out really well. No trimming needed & routing the harness was straightforward.

    The retrofitted Depo headlights are no deeper than the Depo was prior to the job. I didn't remove the rubber behind the headlights, didn't need to modify the washer fluid reservoir, & again no trimming was needed on any of the radiator support or the headlight support panels.

    Relay mounting for HID harness...
    IMAG0547.jpg

    Passenger side ballast mounting...
    IMAG0548.jpg

    Driver side ballast mounting...
    IMAG0549.jpg

    Stock lighting...
    IMAG0550.jpg

    HID lighting...not totally aligned correct yet...
    IMAG0551.jpg

    Driver side headlight...
    IMAG0552.jpg

    Blue/purple cut-off...
    IMAG0554.jpg

    Light on garage door...
    IMAG0558.jpg

    Purple/blue cut-off...
    IMAG0559.jpg

    Lights 4 feet away from a Honda...
    IMAG0560.jpg

    All done...

    ---------- Post added at 12:01 AM ---------- Previous post was Yesterday at 11:53 PM ----------

    My overall impression of this retro so far is that the light quality is amazing. With 14 hours of work over a few weeks into these it was going to suck if heat was going to be a problem. After driving around with them for a few hours the housing were a little warmer than the outside temp.

    So far I'm thrilled with the results...I do wish I tested the stock Depo projector with a DDM or similar setup just for comparison but oh well. I think the Depo projector out of the box would give some excellent results but the cut-off, quality, & experience I had doing a true retrofit was totally worth it.

    Cameron
     
    Last edited: Feb 12, 2011
    M1Gunner likes this.
  5. waxworkz

    waxworkz Full Access Member

    Posts:
    689
    Likes Received:
    0
    Joined:
    Aug 9, 2010
    Name:
    JR
    fu-king amazing. nice job man. now i know what i have to do to my depos when i get them
     
  6. DenaliAK

    DenaliAK Colder than you

    Posts:
    2,178
    Likes Received:
    9
    Joined:
    Aug 1, 2009
    Location:
    Alaska
    Name:
    Scott
    Awesome job. You put some time into it.

    The cutoff is sick...nice and sharp, great color.

    Good job!! Now streamline the process and you could charge guys on here to do it for them....

    ;)
     
  7. Kman

    Kman Full Access Member

    Posts:
    416
    Likes Received:
    2
    Joined:
    Feb 10, 2011
    Location:
    Southern California
    Name:
    Keith
    Looks good. Why is there a shadow of light above the cutoff in the one pic? Where did you get your Depos from? If you got them off eBay, which seller?
     
  8. 01Konvict

    01Konvict Boats n Hoes

    Posts:
    2,715
    Likes Received:
    629
    Joined:
    Jan 16, 2011
    Location:
    Raleigh/SML
    Name:
    Wade
    diggin the retrofit, I just completed one on my accord. I used Morimoto mini h1s for the ease of installation. Going with a good projector is key. I think I may have to go retro my yukon.
     
  9. DenaliAK

    DenaliAK Colder than you

    Posts:
    2,178
    Likes Received:
    9
    Joined:
    Aug 1, 2009
    Location:
    Alaska
    Name:
    Scott
    Those Morimoto Mini's are pretty slick little projectors.
     
  10. killer20072001

    killer20072001 Yep

    Age:
    31
    Posts:
    1,316
    Likes Received:
    11
    Joined:
    Sep 2, 2009
    Location:
    Oklahoma
    Name:
    Kelly
    SWEEET write up. A Mod should sticky this ASAP.
     

Share This Page