CB7Tuner Forums

Go Back   CB7Tuner Forums > Site Features > DIYs > Exterior DIYs

Reply
 
Thread Tools Rating: Thread Rating: 4 votes, 4.75 average. Display Modes
Old 12-06-2006, 12:38 PM   #1
maroonaccord2.2
CB7tuner Member
 
Join Date: Jan 2006
Posts: 2,276
maroonaccord2.2 may have said something they shouldn't have...
TSX projector Retrofit in USDM housings

TSX Retrofit DIY

Click HERE for the finished video DEMO

After much brainstorming and research on HIDPlanet.com, I finally decided to tackle a retrofit project of my own. I decided to use the Acura TSX projectors for their output, manageable size, and affordability. My retrofit headlights are USDM pieces that I purchased from another member (thanks 93cbh22), because I like the look of the US pieces and love the affordability. I have about 60+ hours into this project to get it done right, so don’t expect a weekend deal. On a scale of 1-10 for difficulty I give this retrofit about an 8, it was very time consuming but completely worth the end result.

I purchased my TSX projectors off of eBay for $150…..I’ve seen them more and less expensive and trust me they’re worth every penny. The TSX projectors require the use of a D2S based HID bulb, and applicable ballast for each side. I ended up purchasing 2 used Philips Generation III ballasts locally for about $200. These ballasts are stock OE equipment on many new Audis. Also purchased a pair of new Philips D2S 4300k bulbs (PN 85122) for my application, this is the best color/temperature bulb for the application as it produces the most usable light. This are also the factory equipt bulbs in the TSX projectors.

The infamous TSX color mod

Color modding can be completed on a variety of HID projectors, and the TSX is one of the easiest to do this on. Color modding simply increases the area of color shift at the projectors cutoff (where light ends/begins) point. It requires that you shim the reflector bowl (rear of projector) away from the lense housing (front of projector) with 2-4 #8 washers at the BOTTOM and not the top. Below is a picture that shows how the color mod is completed and the results of a proper color mod.

TSX projectors

The bulbs (Philips D2S 4300k)

Reflector bowl and internal cutoff shield w/righthand step

Color mod

Color at cutoff



TSX dimensionsAcura TSX Low Beam (Stanley):
Diameter = 71.05mm
Height = 85.30mm
Width = 120.80mm
Length = 156.45mm
Length(seat of the lens to mounting holes) = 42.00mm
Length(mounting holes to end of bulb) = 96.95mm
Width(between top mounting holes) = 100.45mm
Width(between bottom mounting holes) = 103.45mm
Height(between mounting holes) = 41.50mm

(referenced HIDPlanet for dimensions)

Where to begin

Getting started initially was difficult for me because I hadn’t tackled a retrofit project before. Studying up on other peoples retrofit projects provided me with a more enhanced knowledge base to begin with, and increased my chances for a proper and LEGAL retrofit result. I soon learned that you can never know too much about lighting……

Getting your hands dirty

The first order of business was determining just how to mount the projectors. The hardware needs to be solid, but also allow some room for adjustability. There are multiple factors to consider when mounting projectors in ANY headlight:

1)Vertical adjustment of the projector
2)Horizontal adjustment of the projector
3)Rotational adjustment of the projector
4)Clearance for retrofit re-install into your vehicle
5)Providing a tight, weatherproof seal for the modified housings (avoiding fog/condensation issues)
__________________
1992 Accord LX - SOLD

Last edited by maroonaccord2.2; 06-10-2007 at 07:50 PM.
maroonaccord2.2 is offline   Reply With Quote
Old 12-06-2006, 12:39 PM   #2
maroonaccord2.2
CB7tuner Member
 
Join Date: Jan 2006
Posts: 2,276
maroonaccord2.2 may have said something they shouldn't have...
TSX projectors with mounting studs attached

Here are the bezels that I used, ACE 2”pipe flanges…..about $2.79 each. They just require a little trimming with the dremel for a flush fit, then you JB weld them on from the backside

First you’ve got to pull the stock headlights apart, for me that meant the oven at 225* for about 10-12 minutes, then trim a hole in the back with a dremel. Don’t cut it HUGE!!! I dremelled along a seam on the rear of each housing, and trimmed it larger a little at a time, just take your time here.


Projector set in at approx. full depth


Here are the pics of my projectors set in the housings, I just centered it perfectly and used a marker to index where to drill the four holes. Make sure to have your hardware snug on the projectors, this will ensure more accuracy while indexing the holes.



Once the holes were cut to size I taped off the highbeam reflector, and went to town with the BBQ flat black

I also pulled the projectors apart, remove the lense clips, and painted the front half flat black with the same paint

After things had dried, I re-assembled to see what they looked like. Please not that I also wrapped the seam between the bowl and the leanse housing with aluminum tape to keep light from escaping. This also had to be painted flat black before final assembly.

Test with with bezel and glass (high beam still taped off)

Test fit, no glass…..you MUST insert some shims to secure the bolts against during the finally assembly


I used 3” PVC couples to enclose my headlights, and a 3” rubber cap to seal it all off. Cheap parts from Lowes/The Home Depot

JB weld works GREAT for this, just make sure to scuff both contact surfaces and clean them off well. The PVC should be centered both horizontally and vertically on the back of the OE housing. You’ll need to do some trimming to get a snug fit before applying the adhesive.
__________________
1992 Accord LX - SOLD

Last edited by maroonaccord2.2; 12-06-2006 at 12:55 PM.
maroonaccord2.2 is offline   Reply With Quote
Old 12-06-2006, 12:40 PM   #3
maroonaccord2.2
CB7tuner Member
 
Join Date: Jan 2006
Posts: 2,276
maroonaccord2.2 may have said something they shouldn't have...
I used some plastic scrap and more JB weld to close off the opening on the top

As you can see, I had to dremel the baskets for clearance. On a JDM (no basket) housing this obviously would not be an issue



I got a whole inch of space to spare!!!


The Wiring Harness

After extensive research and advice from other retrofitted foes, I decided on a stand alone harness for my ballasts. Now, when warmed up and running the ballasts only draw about 35 watts of current, but on startup it can be upwards of 80+ watts!! This is NOT good for the small factory harness wires. Here are some pics of what I fabbed up.

My harness minus the fused link…..that was installed during the headlight swap out.

Ballast protection, just don’t seal them up 100% as they need to breathe. I used some Tupperware-style containers that have locking lids and trimmed them for the pigtails in and out.

You MUST have a dremel for this DIY, did I mention that? lol


Driver’s side ballast, I sacrificed the cruise control…..it barely gets used anyhow

Passenger side

Here’s the passenger side installed and running on the car w/no glass! This is a must for aiming them before you make things permanent. (adjustment is vertical/horizontal/rotational)

__________________
1992 Accord LX - SOLD
maroonaccord2.2 is offline   Reply With Quote
Old 12-06-2006, 12:40 PM   #4
maroonaccord2.2
CB7tuner Member
 
Join Date: Jan 2006
Posts: 2,276
maroonaccord2.2 may have said something they shouldn't have...
Driver and passenger side during the aiming process, time to align the projectors and shim them with washers if necessary before final fitment.

As you can see, the passenger side needs a tad of rotational adjustment counter-clockwise….probably just a few degrees. It’s important to note that they are supposed to be aimed down a little bit from horizontal. (2.1-2.5” drop over a distance of about 25 feet)

Aiming diagram


Once aligned and shimmed, it’s time to make them more permanent. I used some shims (trimmed BIC pen) and globs of RTV sealant to make sure things are water tight.


The PVC cutouts are for the large D2S ballast plugs



Now it’s time for the glass. I used a NISSAN butyl rubber headlight/taillight sealer (part# B-1756) to close them up. It will allow me to pull the headlights apart in the future if need be after a trip to the oven……silicone or liquid nails wont allow you to do that. You simply apply the sealer (stretch and roll it out to size) in the headlight bucket, pop the entire headlight in the oven to soften the butyl rubber for about 8 minutes at 225*, and put the glass on w/the OE clips.

Finished product


On the car, yeah it’s really dirty and cold….it’s the middle of winter so chill.





There are pics of my cutoff coming, so stay tuned!!!
__________________
1992 Accord LX - SOLD

Last edited by maroonaccord2.2; 12-06-2006 at 12:45 PM.
maroonaccord2.2 is offline   Reply With Quote
Old 12-06-2006, 01:11 PM   #5
d112crzy
CB7tuner Member
 
Join Date: May 2005
Location: The Great NW
Posts: 11,650
d112crzy seems to have made some friends!
get pics of these babies in action!
__________________

CrzyTuning now offering port services
d112crzy is offline   Reply With Quote
Old 12-06-2006, 02:24 PM   #6
blackice
CB7tuner Member
 
Join Date: Oct 2005
Location: Redmond, Washington State
Posts: 1,575
blackice is cool... so far.
Very nice writeup Russ, I can't wait to have you help me on my s2k projector project
__________________

Retired 1990 Accord LX Coupe
Project 240SX
Quote:
Originally Posted by chillin943
anyone kno if i can just make a hot wire for v-tec off the horn??
Vouches: Bought from: smseagren83, phatdoughnut, uk - accord, lucid, iamnemo, accord_inspire, 2point6, chopstickz, djcaz_aom, rosko
blackice is offline   Reply With Quote
Old 12-06-2006, 02:57 PM   #7
Dom
Contributing Member
 
Join Date: Jan 2006
Location: new jersey
Posts: 811
Dom may have said something they shouldn't have...
Send a message via AIM to Dom
nice write up!!

they look real good..

is it a big difference driving at night? can you really see more of the road??
__________________
.............................-----------------93 Ex Coupe[/color]-----------------


.



My CD7
Dom is offline   Reply With Quote
Old 12-06-2006, 03:39 PM   #8
Bongo
Contributing Member
 
Join Date: Jan 2006
Posts: 839
Bongo is cool... so far.
those things look sick. I can't wait to start mine. Thanx for the DIY
Bongo is offline   Reply With Quote
Old 12-06-2006, 03:41 PM   #9
maroonaccord2.2
CB7tuner Member
 
Join Date: Jan 2006
Posts: 2,276
maroonaccord2.2 may have said something they shouldn't have...
Quote:
Originally Posted by 93cb7ExCoupe
nice write up!!

they look real good..

is it a big difference driving at night? can you really see more of the road??
I'll post some pics tonight, the difference is massive. When I'm driving in the dark on the freeway, you can't even tell that other peoples lights are on.....it's like you're dwarfing them. The light is controlled, and there's a TON of it.
__________________
1992 Accord LX - SOLD
maroonaccord2.2 is offline   Reply With Quote
Old 12-06-2006, 04:09 PM   #10
Sthrnba711
CB7tuner Member
 
Join Date: Apr 2005
Location: Statesboro/Alpharetta, Georgia
Posts: 382
Sthrnba711 is cool... so far.
Send a message via AIM to Sthrnba711
Great job man. Looks very similiar to the retro i did except i didnt use any bezels. The difference between TSX retrofit and stock headlights is completely night and day. Keep up the ideas and work people and the poor stock lights will all be gone.
__________________
1991 Black Accord Coupe
Sprint Lowering Springs
Neuspeed/Koni Sport Shocks
Suspension Techniques Front and Rear Sway Bar
17" Motegi DP6 with Bridgestone Potenzas
TSX HID Retrofit with 4300K Bulbs
http://www.cardomain.com/id/sthrnba711
Sthrnba711 is offline   Reply With Quote
Old 12-06-2006, 04:17 PM   #11
ap716
CB7tuner Member
 
Join Date: Mar 2005
Posts: 415
ap716 is cool... so far.
wow, nice retros.
ap716 is offline   Reply With Quote
Old 12-06-2006, 04:28 PM   #12
cannedcb7
CB7tuner Member
 
Join Date: Oct 2006
Location: killa kali
Posts: 111
cannedcb7 is cool... so far.
good write up!!!! my friend is trading me some tsx headlights with hid's and i thought i wasnt gonna need to buy anything else. so i guess im gonna have to pass on em cuz i aint got a job to buy the extra stuff.
cannedcb7 is offline   Reply With Quote
Old 12-06-2006, 05:01 PM   #13
ACC0RD22
CB7tuner Member
 
Join Date: Dec 2004
Location: Home = CT, School = PA
Posts: 1,847
ACC0RD22 is cool... so far.
Send a message via AIM to ACC0RD22
ill definitley be referring to this thread if I ever decide to do a retrofit.

awesome writeup dude.
__________________
-Mark-
CB7
CD5


And if i could swim I'd swim out to you in the ocean
Swim out to where you were floating in the dark.
ACC0RD22 is offline   Reply With Quote
Old 12-06-2006, 06:18 PM   #14
vinbon63
CB7tuner Member
 
Join Date: Sep 2005
Location: Canada
Posts: 1,139
vinbon63 is cool... so far.
This is definately a great write up, good job! I cant wait to see more pics.
__________________

1992 Honda Accord Coupe LX
vinbon63 is offline   Reply With Quote
Old 12-06-2006, 07:25 PM   #15
blizzard335
Freeballer
 
Join Date: Aug 2006
Location: Teh futurez, RHD land
Posts: 4,314
blizzard335 seems to have made some friends! blizzard335 seems to have made some friends!
Send a message via AIM to blizzard335 Send a message via MSN to blizzard335 Send a message via Yahoo to blizzard335
this definitely is a must read..

must do!

now to find some time..
__________________

Click sig to view MR thread

Links to other rides:
Honda Accord Euro-R
Honda Odyssey Absolute
Honda City I-DSi
Honda Stream
blizzard335 is offline   Reply With Quote
Old 12-06-2006, 10:39 PM   #16
ProJect
Accord of the Month: December 2006
 
Join Date: Jan 2005
Location: Ontario California
Posts: 2,509
ProJect is cool... so far.
great write up man, i would of done a diy, but i thought it might take me a long as time, but you did a fantastic job and hey in this pic it looks exactly like mine at night, it looks like a lil wu-tang clan emblem off the glass, lol keep it up

__________________
ProJect is offline   Reply With Quote
Old 12-06-2006, 11:00 PM   #17
Davids92Accord
CB7tuner Member
 
Join Date: Mar 2006
Location: Los Angeles
Posts: 4,528
Davids92Accord is cool... so far.
good write up man this helps alot of people out whenever they want to do the retrofit
__________________

CLICK ON SIG FOR MEMBERS RIDE
"2SIIC"
Authentic Jerseys for sale
http://www.cb7tuner.com/vbb/showthread.php?t=188314
Davids92Accord is offline   Reply With Quote
Old 12-07-2006, 12:46 AM   #18
Blk EX Coupe
Contributing Member
 
Join Date: Feb 2004
Posts: 3,968
Blk EX Coupe is cool... so far.
This thread is making me want to do a retro in my jdm headlights. Do you have a picture of how wide the light beam is?
__________________
Blk EX Coupe is offline   Reply With Quote
Old 12-07-2006, 07:24 AM   #19
blizzard335
Freeballer
 
Join Date: Aug 2006
Location: Teh futurez, RHD land
Posts: 4,314
blizzard335 seems to have made some friends! blizzard335 seems to have made some friends!
Send a message via AIM to blizzard335 Send a message via MSN to blizzard335 Send a message via Yahoo to blizzard335


why do USDM's have those little nipples?

nice light spread and output, tho..
__________________

Click sig to view MR thread

Links to other rides:
Honda Accord Euro-R
Honda Odyssey Absolute
Honda City I-DSi
Honda Stream
blizzard335 is offline   Reply With Quote
Old 12-07-2006, 08:13 AM   #20
maroonaccord2.2
CB7tuner Member
 
Join Date: Jan 2006
Posts: 2,276
maroonaccord2.2 may have said something they shouldn't have...
Quote:
Originally Posted by Blk EX Coupe
This thread is making me want to do a retro in my jdm headlights. Do you have a picture of how wide the light beam is?
Not a good one, but to give you an idea.....

You can also see the corner of my garage opening let up, and that's off to the side quiet a bit. Basically when you're driving next to other cars on the freeway you can clearly see your cutoff on their doors.....even when you're really close. So it's pretty broad.

Quote:
Originally Posted by blizzard335


why do USDM's have those little nipples?
From what I've been reading they're for aiming the headlights, could be for a jig or tool they use at the factory.....I'm not really sure. In any case, the fact that my lenses are pitted some affects output moreso than the nipples.

I like saying that word.... Nipples..... lol
__________________
1992 Accord LX - SOLD

Last edited by maroonaccord2.2; 12-07-2006 at 08:16 AM.
maroonaccord2.2 is offline   Reply With Quote
Reply

Thread Tools
Display Modes Rate This Thread
Rate This Thread:

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump


All times are GMT -5. The time now is 10:56 AM.


Powered by vBulletin® Version 3.7.1
Copyright ©2000 - 2019, Jelsoft Enterprises Ltd.