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Bi-LED Projector Headlight Build

1.1K views 19 replies 6 participants last post by  Brandon Craig  
#1 ·
Well, I've missed out on two sets of projector headlights here lately so I decided to build my own set.

First, I removed the bulb sockets, rubber seal, and screws from the housing.

I baked the headlights at 250 degree for 10 minutes and pulled them apart.

With everything apart, I pained the reflector bowls a satin black and then installed the bi-led projectors.

I used a 9007 harness pigtail to adapt the projectors to the OE wiring. I'm having an issue getting the high beams to work but I'll get that figured out.

I leveled the beams before reinstalling the lens. To do that, I baked the lights at 250 with new butyl and the lenses set in place. I pulled them out and put the 4 screws back through the housing and then baked for another 5 minutes. Once that was done, I tightened the screws again to make sure they were sealed tight.

Put the lights back on the X and drove to a parking lot to adjust the light height. The picture shows the cut off at 25 ft.

Enjoy!

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#3 ·
Your right side beam is misaligned rotationally about 10 degrees. To fix it you'd need to reopen the lenses. I don't use LEDs in builds, I do HIDs, but however u mounted it needs to be redrilled if it was done in a 4x4 mount, or rotated and jb welded to prevent further rotation from road vibrations or offroading, etc.

Also be super careful, the LED series are extremely heavy and the adjustment screws are plastic. If youre honestly happy with the cutoff height I'd jb weld it in place.

Also also, lol, these xterras love to leak moisture in. I would recommend to remove and rtv seal the edges and rear seals of the assemblies.

They look great, honestly, just some constructive advice from a guy whose built a ton of these before. The mini gatlings look great too. Good job all around!

I really like the clear outers, too bad the inside turn signals arent chrome like the others. Could always swap the trim and lense pieces..
 
#4 ·
I have been entertaining whether to try this myself. For the clear marker lights - do you have to use an amber bulb/led since it is clear?
Yea, for the side markers you would need an amber bulb if you wanted it to glow amber. I currently have white LEDs in there and a set of amber on the workbench to see what I like better.

Your right side beam is misaligned rotationally about 10 degrees. To fix it you'd need to reopen the lenses. I don't use LEDs in builds, I do HIDs, but however u mounted it needs to be redrilled if it was done in a 4x4 mount, or rotated and jb welded to prevent further rotation from road vibrations or offroading, etc.

Also be super careful, the LED series are extremely heavy and the adjustment screws are plastic. If youre honestly happy with the cutoff height I'd jb weld it in place.

Also also, lol, these xterras love to leak moisture in. I would recommend to remove and rtv seal the edges and rear seals of the assemblies.

They look great, honestly, just some constructive advice from a guy whose built a ton of these before. The mini gatlings look great too. Good job all around!

I really like the clear outers, too bad the inside turn signals arent chrome like the others. Could always swap the trim and lense pieces..
I appreciate the tips! I didn't see the misalignment in person, it only became clear in the photos. The projectors are shaft mounted through the reflector bowl. I need to pull the assemblies back out and rewire for functioning high beams, I'll adjust and JB Weld then!
 
#5 ·
Did u cut down the rear of the projector bowl and weld on a machined washer and use a shaft lock nut? Or was it the 4 cuts into the bowl?
Morimoto equipment? Im not understanding how the high beams arent integrated into the headlight harness...

If u used an adapter harness, I'd try repinning and swapping the two outer leads. The 9004 and 9007 headlight harnesses have the same exact wiring except the high is the low and vice versa. I'd bet u didnt do anything wrong and its the harness wired backwards.

When I get morimoto harnesses, even when I specify, they always send me them pinned backwards and I have to repin or the high beams won't work.
 
#6 ·
Did u cut down the rear of the projector bowl and weld on a machined washer and use a shaft lock nut? Or was it the 4 cuts into the bowl?
Morimoto equipment? Im not understanding how the high beams arent integrated into the headlight harness...

If u used an adapter harness, I'd try repinning and swapping the two outer leads. The 9004 and 9007 headlight harnesses have the same exact wiring except the high is the low and vice versa. I'd bet u didnt do anything wrong and its the harness wired backwards.

When I get morimoto harnesses, even when I specify, they always send me them pinned backwards and I have to repin or the high beams won't work.
No, these aren't Morimoto sadly. The projector assembly has a 20mm long threaded shaft that goes through the reflector bowls, through a keyed washer then gets locked down with a large jam nut.

The projector has 4 leads coming off of it, two power the LED and two power a high beam shutter. I have the low beam ground going to center pin on the 9007 adapter pigtail and low beam 12v to one of the outside pins but when I connect the high beam shutter to the opposite pin and try them, I get nothing. No high beam shutter and I lose low beam lights. I checked the Xterra side of the harness, when I switch from low to high beam, I am losing 12v at the low beam pin and no longer have ground continuity at the middle pin.

I can cycle the high beam shutter manually using a 12v input and ground.
 
#11 ·
Sure, I deleted the pics I had a while back, and anyways I dont know what kind of harness youre running (in terms of the colors that the wires will be) but I did see a pic that had a blue plug. I'm going to assume that your harness only plugs into one side of the oem headlights, thats fine. Unplug that blue plug and, leaving the center wire attached where it is, switch the two outside wires. There should be one to the lower right and lower left of the center.
So ur gonna want to de-pin both of these wires and re-pin them in the slot the other was in. That should fix it. Let me know how it goes
I was trying to wire the projectors directly to a 9007 adapter. I ordered some bi-xenon 9007 harness and will get them wired in this weekend.

I did this recently to mine, and still need to actually put the time into correcting it, but the low beams are meant to shut off when the high beams are on. Since the high beam only drops the cutoff, the low beam that actually supplies the light loses power. Theoretically you can solve this with a jumper between high and low beams with a diode preventing current going from low beam to high beam.
I found some (almost) plug and play harnesses that should work, will just have to adapt to the projector. I bought both and will see which one is better for us:


&

 
#12 ·
I was trying to wire the projectors directly to a 9007 adapter. I ordered some bi-xenon 9007 harness and will get them wired in this weekend.



I found some (almost) plug and play harnesses that should work, will just have to adapt to the projector. I bought both and will see which one is better for us:


&

This is what I was saying is the problem, notice it says 9004 9007 harness? The 9004 and 9007 are the exact same 3 pins in same place but the low-high-ground configuration is different. Any harness u get is going to default to the 9004 setup. I dont know why they do this, maybe the 9007 is less common. They only list it as a 9007 also because by repinning the blue plug it becomes a 9007.

What I know for sure is any morimoto harness I've ever used, if I do not repin it, when engaging high beams everything shuts down, because the low beam loses its input and the high beam input isnt in the right place. So what I do is swap the outermost pins, left to right and right to left, leaving the center alone, and it voila it works. I assume that means the 9004 setup is opposite the 9007, never bothered to look it up, all I know for sure is it works.
 
#17 · (Edited)
@curveball3110 @Z1_Kameron

Both harnesses were delivered and I had a chance to test both and can confirm that both work for my application. Both got the high beam shutter operational while retaining the low beam power.

I ended up using the smaller harness (iJDMtoy Easy Relay) since it was more compact. The XtremeVision harness worked just as well but required more connections and just seemed like overkill since the LED and shutter don't demand a huge amperage draw.

Hope this information helps someone along the way!
 
#19 ·
how many watts are these bi-led projectors ? 35 or 55 watts ?
the wiring harness you ordered doesn't mention any info of the wattage they support !
i've ordered these : This item was discontinued - Temu

and the output is so damn good, but am having the same issue with the high beams !
am afraid the harness you linked doesn't support the 55w bi-led projectors am using and they over head or cause a problem with my original Xterra headlights wiring!