Moar pics!!

 

everything apart , wright now working on making bracket that will allow me to rotate projector without changing left/right up/down position

 

Please let us know what you figure out for this, I'd like to do this on mine while I am doing this conversion, would make fine tuning A LOT easier.

 

Rotational adjustment would be sweet! It will be quite complicated since the adjustment will have to be made into a bracket that rotates the projector housing only while still holding it steady to the reflector bowl. There isnt much room back there as is, so im very interested in seeing what you got cooking there!
As far as right/left adjustment, the easiest would be to extend one of the lower outside mounting points on the main bowl reflector much like the top up/down adjuster is.
Good luck and post up pics!

I got to sort all my pics out so i can get them posted up.

 

do it!!!!!!!!!!!

 

ok got my pics up last night.
EDIT
(Sorry guys, got thumbnails up to slightly smaller pics, hope that helps.)

The build up pics are just like powerz' pics at the
beginning just with a different background so no sense in posting up doubles.

Here is my initial parts setup.
Two FX-Rs, Two complete M45 lo only with three piece shrouds.
two matsu ballasts two morimoto three fives.
Four apollo shrouds and misc other items.
th_Thesetup.jpg?t=1296270793
I initially wanted to use the M45 shrouds with the FX-Rs in the housing but the projector would have to be heavily modified to use them so that went out the window. The chrome areas on the M45 also had a green tinge to them so they would have to be sent for a clean re-chrome.
(crappy shot with a broken headlight assembly)
th_M45projector.jpg?t=1296270793

So no need to post install pics as there are already plenty on here, and well i was to excited doing it that i didnt take any.
But here are some pics of what to do to mount the apollo shrouds.
First and foremost, you have to grind/sand/cut down the two small nibs that are on the bottom of the FXR near the screw for the hi/lo/ solenoid.
(borrowed pic from the web)
Take these all the way down to the flat area where the screw mounts.
th_Projector036.jpg?t=1296270793

The shrouds have to be trimmed just a bit.
The red indicates what will be removed in this pic. Both small "vents" on either side will be cut and the bottom will need to be cut as shown.
th_Projector035.jpg?t=1296270793


When you do the two sides, trim enough so that when you hold the shroud level (the two blue lines are lined up) the inner cup (red) is cut even with the top of the outer cup (green)
th_Projector033.jpg?t=1296270793

This is a basic shape of the cut on the bottom. Once you do the two vents youll have to trim this a bit at a time to get perfect around the screw and peg area we trimmed before on the FXR.
th_Projector034.jpg?t=1296270793

I actually took the screw out (see projector pic above) and kept test fitting till the shroud sat perfect on the lense and there was about 1/16 gap all around the cut. Once its trimmed, simply make a very very tiny fingernail shape notch on the outer ring where the screw hits.

That should get your apollos fitting nicely. Remember, take the black rings, and superglue them to the shrouds and let them sit BEFORE putting the headlight all together. As a matter of fact, do it before modifying the shroud.

 

Nice! The pictures will help more people out that choose the apollo shrouds.

Any way to make the pics smaller?

 

Heres some pics of the reflectors and the projectors installed and aiming

.
my rotational adjustment as well as left/right adjustment is damn near dead on.
(sorry for the previous large pics, Click for larger pics)
th_IMAGE_324.jpg?t=1296190866

th_IMAGE_323.jpg?t=1296190866


I also decided to mount the OEM ballasts on the housing itself.
No dumb hanging ballasts. Just three 10/24 allen head bolts and some tubing per side.
th_Projector001.jpg?t=1296190866

I started off by picking a nice place, this fit perfect in the small space the F150s have to work with.
th_Projector005.jpg?t=1296190866
th_Projector002.jpg?t=1296190866

Marked my locations
th_Projector006.jpg?t=1296190866
Drilled, then tapped them

th_Projector007.jpg?t=1296190866

Cut some tubing to length

th_Projector003.jpg?t=1296190866

And went for a test fit.

th_Projector014.jpg?t=1296190866

test fit in truck,

th_Projector018.jpg?t=1296190866

And marked where i needed to trim for the connector.
th_Projector017.jpg?t=1296190866

Took all the spacers out, and cut some for the other side and shot them trim black
th_Projector023.jpg?t=1296190866

I then took some black RTV to the threads before the final assembly,
th_Projector026.jpg?t=1296190866

I also made a spot for the stock wire tie to screw to.
th_Projector029.jpg?t=1296190866

then i installed the OEM plug on harness and ran it thru my new hole
th_Projector024.jpg?t=1296190866


Right side all installed
th_Projector032.jpg?t=1296190866

nice close up
th_Projector030.jpg?t=1296190866

Repeat for other side,
th_Projector037.jpg?t=1296190866

core support

th_Projector038.jpg?t=1296190866

A few more pics on the slideshow.

 

nice! those pic are big can you please resize them? I make small progress today with my bracket , just don't have time to finish but so far its going ok

 

Sorry guys I was so excited about fixing my camera that i forgot they were 12 megapixel pics...

Im running a 17 monitor on 1280 X 1224 and the links show up as 21% and look a nice size, let me know if anyone wants a smaller res pic, but i really dont want to resize all of them. My old PC doesnt have the disk space to multitask as fast i do lol.

 

They're fine.

 

Thanks powerz69 for making such a great write-up it was very helpful in being able to know what I was getting into before I did anything. I'll get some pictures up of the finished product soon.

 

Thanks! That means a lot. I'm glad you were able to use it as a guide line. I'm enjoying how everyone is doing their little spin on things. The next thing I'm thinking how to do is projectors in the round fogs.

 

D2S minis! I know they will fit the 04-05 fogs, i bet they'd fit yours too with some modification.

 

Yeah I'm kinda leaning towards the D2S minis, or the ford Fusion fogs. Just need a small sealed projector. The hardest part is picking a good one that will work.