DIY: x70 Projector Retrofit

[EstVolvo]

The deeper I dig, the more I find.
I read that somebody had a bad experience with the cheap projector that I was looking at on Amazon. He said that it started fading just after three months.
Another finding:
I'm not sure that the light pattern is acceptable on picture #12 (car parked in front of garage). On the left side (driver's side) the beam gets really skinny and there is absolutely no light close to the ground.

[Darkfleet]

I should probably post some updated pics - I think picture 12 was taken back when I still had fluted lenses (prior to all the sanding). I also haven't really dialed down my aim perfectly yet. I'll try to get these in the next week or so maybe taken from lightly further back so you can get a good idea for the beam pattern.

I did some research into these h1 projectors and you will notice that very close up there is a lower "semi circle of light" but then once you get maybe 5 feet out the light is all on the ground. This is the same on all projectors h1 mini "classic projectors" due to the shape of the reflector bowl. If up close (less than 5 feet) your light wont be touching the ground yet and you will see the lower semi circle in the pattern. Doesn't really bother me although there are thing you can do like foreground limiters to fix this issue. You could also buy the newer Morimoto mini h1 7.0's which have that flatter pancake reflector to eliminate that issue.

After driving around with these I am still very happy with them. I have seen the one amazon reviews about the reflector getting eaten by UV.. I guess only time will tell. I took the cheap projectors as I wasn't sure if it was going to work in the first place and did not want to invest a lot, I also felt after looking at pictures for multiple brands they seemed to be designed all equal (just the h1 classic). Pretty sure all the non morimoto ones are just the rejects that didn't quite make QA for some reason. Either way now that I'm with this setup, throwing in a new expensive projector would not require a lot of effort.

I may spend some time in the future tuning these projectors with bending the cutoff shield and spacing the lens to get optimal coverage. Sound more like a summertime kind of job though.

[FLXC90]

OP-great job, looks well-done, now just the test of time! Try a picture against a wall from about 30-35 feet. thay will give us a good idea of where the light really goes in traffic. ( Now I have some use for my 2 sets of spare housings with tan "refelectors"

[EstVolvo]

First, when I saw this DIY thing here, I was all exited that finally I have an affordable fix for my dim lights ... but now it seems like a $300 Morimoto project.
Here is the story about the durability of Nilight 2.5" Mini HID's (sold through Amazon) that scared me away from the cheap stuff:
https://www.hidplanet.com/forums/forum/ ... ht-mini-h1

[Darkfleet]

Here's some output shots. My aim is not 100% yet still playing around with it but it gives you an idea to the level of lighting. Its great! Even If these wear out and I need to upgrade to the morimotos I will definitely do it. Keep in mind these are all not level surfaces, theres not really a lot of good spots around here with all the snowbanks atm.

Close Up (~15ft)

Far Away(~40ft)

Side Cutoff

[EstVolvo]

Thanks for the updated pictures. Are those pictures taken with the fog lights on?
What was wrong with the original ones that you used first?
What is in there now and where did you get it from?

[Darkfleet]

Fog light on yes, didn't think to turn them off.
Same projectors just posting longer distance pictures. The one in front of the garage did not do it justice.

[mrbrian200]

This might be something to look into regarding the early HID equipped xc90s. Low beam is fine on these but the high beams need desperate help. The halogens on the inside of the headlamp assembly aren't a high beam, they used for DRL. Depending on software/region they may be completely disabled although a bulb is installed and wired to the CEM (as is the case on the one in my driveway, software runs the HIDs as DRL). The potential problem I have read in trying to enable these for high beams is the reflector is designed to spread the light for DRL, not focus forward.
I've eyed the circuit diagram for the lights. Looks like it should be possible control these from the HID height position motor signal, which being two wire I would imagine is controlled by a reversing polarity voltage like the fuel hatch lock. Would either need to be some sort of logic control circuit or a specialized relay that switches on/off with these momentary pulses. A spare fuel hatch lock and a momentary contact switch might just be the ticket provided the extra current draw doesn't risk too much current draw from the HID position feed. Projector lenses would solve the focus issue. When the weather warms I will just have to look into this.

[EstVolvo]

Who sells the 2" sanding discs needed for this project?
Are your original high beams still operational?
Are the HID lights wired in conjunction with your high beams or are they completely separate?
Do I need (is it good to get) something called Canbus:H7?

[FlyingVolvo]

Darkfleet, your thread inspired me to do a retrofit! I still need to tweak them a bit, but here are my results from today's install.

I bought new aftermarket OEM-style headlamps from IPD.

Retrofit

Installed... and yes, painting the trim is on my to-do list.

Poor bumper

Low beam only (35w 4500K HIDs)

Low beam

Low beam + halogen fogs

Low beam w/ fogs

Up close cutoff. Holy lumens batman!

Cutoff