Possibly a simpler way to retrofit your headlights,

Tools needed,
Drill
2 3/4" hole saw
1" dowel rod 6" long
Roll of tape
Flap wheel sanding drum for drills.


Cut your dowel to the desired length 6" will do, longer will work as well.




Find center of dowel and drill a hole a size smaller than your hole saw piloting bit. Mine is a bit off, they make a ring that does as well as a little time would help, I got into a rush.



As straight as possible sink hole saw bit into pilot hole.The dowel is a bit smaller than the bulb socket so rap a few bands of tape around to get it to size.



Insert jig into light and cut away.




Sand in places where necessary as the Fxr projectors are a bit more oval than round.



Shim the housing to get the bowl level in both directions.



Use a 2 1/2" hole saw bit to level/plumb the projector.






By my way of thinking, if the bowl is right, and I match the projector to the bowl then, I should be very close to straight upon installation.
But I will not know for sure until I install them.



I do not have pictures, but once leveled I took a machine screw, dipped the end in paint and lowered it down through the mounting hole to mark where to drill. Start with a small bit 1/8 or so and then move on to the bit size necessary for your screws.

Then attach as listed in the retrofit how to.
I hope this helps, it costs a little more to buy the hole saw bits if you don't have them, however it is faster and much easier to center the hole.

 

Actually a 2 7/8" bit would be perfect, however I could not find one.

 

What a neat idea! This is why I'm glad more and more people are doing this mod.

 

NICE! That looks sooo much easier!!!

 

GREAT idea! Getting the hole perfect was my second hardest step behind aiming the projectors, which may have been even easier had I of done this. Thanks for posting this!

 

I did it with the Dremell at first, but mine is cordless and the battery kept dyeing on me, so I thought there must be a way to do this and center the hole better.

My thought with the level is that if the bucket is aimed correctly, and I match my projector to that I should be pretty damn close to strait. We'll see in a week or so as I ordered the wrong Halos from TRS and have to wait on the exchanged set to arrive.

The other thing I might add is, that I enlarged the mounting holes in the projector housings to allow me to fine tune the rotational alignment of the projector.

 

What an ingenious idea! Just for the amount of dust it must cut down on is worth it right there.. Defiinatly going to use this method on my next retrofit for sure. Thanks for sharing..

 

That's for sure! The dust was unreal when i retrofitted my heads.

 

Where is the "how to" for the retro-fit located....this looks like a great time saver !!

 

https://www.f150online.com/forums/20...-retrofit.html

Here is the how to, the procedure I listed above is not as much about time as it is about centering your hole accurately. It is faster, very slightly cleaner, but it eliminates a lot of the trail/error sand to fit procedure. You still will need to sand a little as the projectors are slightly more oval than round.

I may be selling this set later after completion, as I have an idea in mind for something a little bit wilder.

 

Thanks for the link, did you use the 3" or the 2.5" ? If you decide to sell shoot me a PM, might be interested in another set.

 

2 3/4" hole saw
it will wobble a bit making a 2 7/8 hole
3" may work but will be a bit big and may introduce to much slop.

 

This was a mis-leading post..sorry. I meant did you use the 2.5" or the 3" FXR (lens) projectors?

 

2.5 I do not believe the threes were available when I purchased them, and I bought them from another member on here, who gave up on retrofitting his own lights.

 

this just convinced me to do my retrofit sooner. was dreading having to dremel out that big of a hole.. even with a die grinder