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Old 10-13-2015, 10:03 PM   #31 (permalink)
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More picture dump. I'm about to go put the headlights back on the car and find somewhere to aim them.

I ended up not using JB Weld to fix the projectors in place; I modified the stock mounting brackets to accept the LED projectors, dremeling quite a bit off.


Then, I attached with nuts, bolts, and generous amounts of Loctite, centering them on the bracket, using the stock cutoff (marked with pen before dremeling) to get the rotation right, and checking by measuring distances from the top and side edges of the housing and comparing with the stock projectors.




I used a PVC pipe fitting from Menard's to fill the hole in the rubber gasket behind the lowbeam, drilling out the center to pass the connector through and using silicon to seal the hole (not pictured). The LED controller and all wiring are inside the headlight housing.


Baked back together and ready to go on the car:


I removed the orange reflector to give them a little cleaner look.


The halogens had a 3" lens, and the LEDs only 2.5", so I had some leeway. They aren't perfectly centered, but close enough for government work.

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Old 10-13-2015, 11:05 PM   #32 (permalink)
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First shot, without having aimed anything yet:


I'll get some distance output shots later tonight.
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Old 10-14-2015, 02:47 AM   #33 (permalink)
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UPDATE: Done!

Leveled them out at 25 feet:


The difference between these and the drop-in LEDs is amazing. Where the latter had no distance and put out almost as much light above the cutoff (through the "squirrel finder") as below it, these have a nice, sharp cutoff (thanks to the TSX-R lenses) with a bit of color, and even pattern with lots of output below it. Distance is excellent, and width seems to be pretty good too. I'm glad now I didn't bother with the quads, as that would have been overkill. And the best part is: 22W total power consumption!


If you're looking to lower headlight power usage, this is the way to do it. Two OEM projectors cost $125-$130, a few bolts and washers are a couple bucks, and the lenses--which don't have to be replaced--were $10 B-stock closeouts. So, all in these aren't much more than the cost of drop-in LED bulbs.
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Old 10-14-2015, 10:44 AM   #34 (permalink)
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I'm definitely interested in this as an upgrade for my Insight, but my only concern is the (still) relatively narrow beam. It might still be worth the tradeoff, and even with some lower powered LED fogs it would draw considerably less than even the HIDs I have installed.
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Old 10-14-2015, 11:49 AM   #35 (permalink)
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I was concerned about width as well, which is why I thought about doing quads at first. But, the beams are wider than they appear in the photo, and after cruising around town for a bit, I went out on some country roads for an hour to try them in the dark. They're about as wide as the halogen/drop-in LEDs were. I might add LED fogs still in the future, but for now I'm satisfied with the performance of these.
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Old 01-05-2016, 05:59 PM   #36 (permalink)
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Just wondering how these are working out and if you still like them?

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