Thomas W Thats a great job!
I was looking at the FX-R for a long time now, because I love the cut off. Thomas proved it could be done so I bit the bullet. I'm on 2 days now with all sorts of problems. The 04-08 headlight is a bit small for the FX-R with the Gatling shroud. I cannot get the clear plastic lens back on without hitting the shroud. I cut the shroud down as far as I could. Now I'm cutting the reflector bowl hole bigger but I can't go to big or I'll hit the horizontal alignment bar. And there is only 3/4 inch in back of head light be fore the frame, and I don't think the frame can be cut. Anyway here is the projector roughed in but hitting the clear plastic so there is no vertical adjustment.



[IMG]https://www.f150online.com/forums/me...-projector.jpg[/IMG]

powerz,
The conversion is looking good! The F150 headlight lense shape does make it tricky to get the projector and shroud in. Their is only about 1/8" max of clearance between my shroud and the headlight lense. If the shroud is what is keeping your lense from going seating completely, you can modify the shroud so it will slide over the projector how ever much you need it to. You can look at the pictures i posted of the modified shrouds to get an idea of what i mean. I did have to do some trimming to the fiberglass headlight support on my truck. I'm not sure how ford has the 04+ headlights attached, but if its similar, you should be able to slide the projector back into the headlight some-more and modify the headlight holder.

If you can get some pics of those area's and of what is hitting with the lense, i'll see if i can't give ya some more idea's to get ya on the road!

Thanks! I'll take more pictures tomorrow on whats happening. As for the shroud I'm very sure after trimming its maxed out. The shroud it hitting the 4 FX-R mounting bold heads. I'm going to trim the bowl more rough fit it and put it in the truck to see exactly how far from the frame it is. I know I will get it it's just the figuring part thats taking the longest. The 2nd light should be very fast after everything is figured out.

powerz
One thing that is hard to see in my pictures ( should of gotten betters ones) is i actually notched the shrouds so they would slide around the projector mounting tabs on the bottom.

You can just barely see the notch in the shroud with this picture. If your shroud is notched and is hitting the bolt heads, you could always go to the hardware store and get some button head allen bolts.

http://img.photobucket.com/albums/v4...t/DSC01997.jpg

I got it done and fits great. I cut the shroud down and got 1/8 '". I also cut the headlight bowl more and got just under 1/4" Now with the clear lens on shroud has 1/8" or just under. Enough room for vertical headlight adjustment. Thanks again Thomas W! I'll start the other light and take pictures like you did and make a link to my new thread.

That looks SICK! I had no idea that the gattling surround would look that well in there. I am partial to that particular surround too.

I need to get off my arse, i have had two spare lights sitting here for well over six months! Once i have it all apart, i think im going to cast a mold of the reflector and mold some clear ones for mine. I hate that orange reflector with a passion.

Post pics up of how you mounted and how much you notched!
You have any plans of doing any backlighting or CCFL rings behind the surrounds? I kinda wanna do a ring behind that will run with the parking lights.

Thanks! ^^^^
I took the other light apart and did the cutout for the projector. I'm taking pictures and going to do a good write up like Thomas W did. I have the measurements for the perfect hole needed for the projector, that was the hardest part. All I have left to do is mount the projector and cut down the shroud. I was not going to add any other lights. After seeing the shroud lit up with a normal bulb, I ordered the CCFL rings. Adding demon eyes into the FX-R projector would be easy to do as well. Just depend on how far you want to go. It's not a circle but the slots in the shroud light up and looks cool to me. If you follow the link that Thomas posted thats a good sale price for everything needed. For this 04-08 mod a dremel is a must, other then that after I do a how to to follow it should be easy. I hope to have it done in 2 weeks. Then we don't have to hijack Thomas' thread. :thumbsup:

Here's a picture of a 100mm halo ring behind the Gatling shroud.



[IMG]https://www.f150online.com/forums/me...e146817-31.jpg[/IMG]

Thomas, you have done an excellent job with this project! You have truly convinced me to do a retrofit on my headlights.

Unfortunately, being in college, I'm going to see if I can put together a "junkyard kit" for mine. If I can find the right vehicle for the bi-xenon projectors, it should be a problem.

Thanks again for the write up!

That is awesome!

How do the high-beams work? Does the cutoff bar inside the projector raise?

Yeah. Most of the bi-xenon are normal projectors that have a "adjustable" shield that moves with the help of a solenoid.

when buying the retro kit, what all did you choose as your scroll down menus?
I know Im going to need the 9007 bulbs and I want the 5000k kit. But as far as the shrouds go whats the difference? and Will I be needing the angel eyes?
this will be going with these headlights-
http://cgi.ebay.com/ebaymotors/97-01...-/140477995968

looks pretty good

do the shrouds move or does the bulb move to do the brights, or is it just the bulb changing to a brighter fillament?

there is no filament in HIDs pat, its a solenoid that raises the cutoff bar

http://www.theretrofitsource.com/ima...nFunction1.gif

the 9007 will be a adaptor to fit in your stock plug and change to a d2s bulbs..

when i order mine it will be 1. 35 W long.. 2. 3five 6000k 3.Not sure yet.. 4. LHD, 5. e46, 6. 9007 bixenon harness