Quest
05-08-2014, 02:44 PM
I did not like the halogens that came with my 96 Legacy. I tried Osram Nightbreakers. While they were an improvement, I still considered the result weak. Rewired the headlights using thick gauge wires, relays and Osram Rally 65 Watt bulbs. Good results but they only lasted 4 months. After that I was frustrated at all the effort so far without good, lasting results. I got a pair of JDM reflector housings with the full intention of replacing the low beam only/wrong side pattern projectors with a setup from The Retrofit Source (TRS). I decided on the Bi-xenon FX-R 3.0 Stage 3 kit with 4300K temperature option. This lamp design is from an Infinity.
Separate the headlight assembly by placing it in an oven at 240°F for 10 minutes then gently pry it apart.
I examined the stock mounting scheme and figured I could mount them without losing the ability to aim them. Making a template of the stock ones prior to removing them will save time later, allowing you to mount the new ones perfectly on the first try.https://sl-i.net/FORUM/images/imported/2014/05/Templateofstockprojector_zps4a78ebe9-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/Templateofstockprojector_zps4a78ebe9.jpg.html)
I lucked out as far as the beam having a level cutoff, the housing and the projector have bases that are level. The "L" shaped cardboard is another template which was used to keep the light centered.https://sl-i.net/FORUM/images/imported/2014/05/P1010335_zps5219fa0e-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010335_zps5219fa0e.jpg.html)
Pictured below you can see the fixed pivot attachment at the bottom right. Top right and bottom left are the black plastic adjusters. I will be using only these 3 mounting points. Doing so will allow full aiming via the stock adjusters.https://sl-i.net/FORUM/images/imported/2014/05/Stockballmountatbottomrightand2adjusters-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/Stockballmountatbottomrightand2adjusters_zpsd6b47939.jpg.html)
Below is the back of the new projector with attachment tabs.https://sl-i.net/FORUM/images/imported/2014/05/Adaptertabsadded_zpsa9e73d29-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/Adaptertabsadded_zpsa9e73d29.jpg.html)https://sl-i.net/FORUM/images/imported/2014/05/P1010364_zpsfc4ae01e-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010364_zpsfc4ae01e.jpg.html)
I used a product called Magic Sculpt,http://www.magic-sculpt.com/ to attach the mounting tabs to the stock plastic adjusters. (and only the plastic adjusters-do not get any on the screw threads) It sticks to most anything, cures rock hard, waterproof and withstands temperatures of 300°F.https://sl-i.net/FORUM/images/imported/2014/05/MagicSculptusedtobondplasticadjusterstom-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/MagicSculptusedtobondplasticadjusterstomountingtabs_zpsf2f388bb.jpg.html)
I had to cut open the housing for access to the horizontal adjuster. I used a hot knife to avoid spewing plastic everywhere.https://sl-i.net/FORUM/images/imported/2014/05/Accessholecutforadjusteradjacenttohighbe-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/Accessholecutforadjusteradjacenttohighbeam_zps2f6c4af8.jpg.html)
I used galvanized sheet metal for patches and siliconed them in place.https://sl-i.net/FORUM/images/imported/2014/05/Projectorisflushwithrearofhousing_zps346-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/Projectorisflushwithrearofhousing_zps346f77d9.jpg.html)https://sl-i.net/FORUM/images/imported/2014/05/Galvanizedsheetmetalusedtopatchhole_zps6-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/Galvanizedsheetmetalusedtopatchhole_zps6de7e22a.jpg.html)
Preheat oven to 240°F, Let the halves heat for 10 minutes and press together. I had to repeat a couple times for a complete seal. The cardboard template I made of the factory one paid off in terms of fit.https://sl-i.net/FORUM/images/imported/2014/05/Afterreassembly_zps202bfad6-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/Afterreassembly_zps202bfad6.jpg.html)
I could not use the factory cup for the back anymore. They have internal threads and were too small anyway. I came up with an idea. That is why I removed some plastic around the mounting ring.https://sl-i.net/FORUM/images/imported/2014/05/P1010373_zps8ad1d6e7-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010373_zps8ad1d6e7.jpg.html)
I found a measuring cup that fit perfect. It was the 2nd largest one (1/2 cup)https://sl-i.net/FORUM/images/imported/2014/05/P1010375_zps094b37a8-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010375_zps094b37a8.jpg.html)
I used a Dremel with the drum sander bit to make clearance for the wires. I was originally going to glue them in place with silicone. I came up with a much better idea. I used self-fusing silicone tape. It's waterproof like rubber and sticks to itself, yet can be removed at a later date for servicing.https://sl-i.net/FORUM/images/imported/2014/05/P1010374_zpsef181e8e-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010374_zpsef181e8e.jpg.html)https://sl-i.net/FORUM/images/imported/2014/05/P1010404_zps94ad0598-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010404_zps94ad0598.jpg.html)
Below is a picture of the cutoff. The adjustment screws work just as they had before. I am able to precisely aim the lights up/down/side to side.https://sl-i.net/FORUM/images/imported/2014/05/P1010385_zps9771078a-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010385_zps9771078a.jpg.html)
https://sl-i.net/FORUM/images/imported/2014/05/P1010395_zps2c56ea2d-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010395_zps2c56ea2d.jpg.html)
https://sl-i.net/FORUM/images/imported/2014/05/P1010400_zps5eff3401-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010400_zps5eff3401.jpg.html)
I need to experiment with my camera. I'm going to try manual settings. These were taken on full auto.
The projectors are Bi Xenon, (high and low beam) coupled with the JDMs factory high beams=Double high beams! They are a sight to behold. The photos don't do them justice.
Update: I have since replaced the factory high beam bulbs with Osram Nightbreaker Plus Unlimited and re-aimed the high-beams. I would like to take some "truer" photos, (in manual mode, not full auto).
I thought briefly about angel eyes... No
I thought about blacking out the reflectors... No
They are just not me. I prefer the clean look.https://sl-i.net/FORUM/images/imported/2014/05/P1010407_zps48bb688e-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010407_zps48bb688e.jpg.html)https://sl-i.net/FORUM/images/imported/2014/05/P1010406_zps8e6dd1f2-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010406_zps8e6dd1f2.jpg.html)
Separate the headlight assembly by placing it in an oven at 240°F for 10 minutes then gently pry it apart.
I examined the stock mounting scheme and figured I could mount them without losing the ability to aim them. Making a template of the stock ones prior to removing them will save time later, allowing you to mount the new ones perfectly on the first try.https://sl-i.net/FORUM/images/imported/2014/05/Templateofstockprojector_zps4a78ebe9-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/Templateofstockprojector_zps4a78ebe9.jpg.html)
I lucked out as far as the beam having a level cutoff, the housing and the projector have bases that are level. The "L" shaped cardboard is another template which was used to keep the light centered.https://sl-i.net/FORUM/images/imported/2014/05/P1010335_zps5219fa0e-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010335_zps5219fa0e.jpg.html)
Pictured below you can see the fixed pivot attachment at the bottom right. Top right and bottom left are the black plastic adjusters. I will be using only these 3 mounting points. Doing so will allow full aiming via the stock adjusters.https://sl-i.net/FORUM/images/imported/2014/05/Stockballmountatbottomrightand2adjusters-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/Stockballmountatbottomrightand2adjusters_zpsd6b47939.jpg.html)
Below is the back of the new projector with attachment tabs.https://sl-i.net/FORUM/images/imported/2014/05/Adaptertabsadded_zpsa9e73d29-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/Adaptertabsadded_zpsa9e73d29.jpg.html)https://sl-i.net/FORUM/images/imported/2014/05/P1010364_zpsfc4ae01e-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010364_zpsfc4ae01e.jpg.html)
I used a product called Magic Sculpt,http://www.magic-sculpt.com/ to attach the mounting tabs to the stock plastic adjusters. (and only the plastic adjusters-do not get any on the screw threads) It sticks to most anything, cures rock hard, waterproof and withstands temperatures of 300°F.https://sl-i.net/FORUM/images/imported/2014/05/MagicSculptusedtobondplasticadjusterstom-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/MagicSculptusedtobondplasticadjusterstomountingtabs_zpsf2f388bb.jpg.html)
I had to cut open the housing for access to the horizontal adjuster. I used a hot knife to avoid spewing plastic everywhere.https://sl-i.net/FORUM/images/imported/2014/05/Accessholecutforadjusteradjacenttohighbe-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/Accessholecutforadjusteradjacenttohighbeam_zps2f6c4af8.jpg.html)
I used galvanized sheet metal for patches and siliconed them in place.https://sl-i.net/FORUM/images/imported/2014/05/Projectorisflushwithrearofhousing_zps346-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/Projectorisflushwithrearofhousing_zps346f77d9.jpg.html)https://sl-i.net/FORUM/images/imported/2014/05/Galvanizedsheetmetalusedtopatchhole_zps6-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/Galvanizedsheetmetalusedtopatchhole_zps6de7e22a.jpg.html)
Preheat oven to 240°F, Let the halves heat for 10 minutes and press together. I had to repeat a couple times for a complete seal. The cardboard template I made of the factory one paid off in terms of fit.https://sl-i.net/FORUM/images/imported/2014/05/Afterreassembly_zps202bfad6-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/Afterreassembly_zps202bfad6.jpg.html)
I could not use the factory cup for the back anymore. They have internal threads and were too small anyway. I came up with an idea. That is why I removed some plastic around the mounting ring.https://sl-i.net/FORUM/images/imported/2014/05/P1010373_zps8ad1d6e7-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010373_zps8ad1d6e7.jpg.html)
I found a measuring cup that fit perfect. It was the 2nd largest one (1/2 cup)https://sl-i.net/FORUM/images/imported/2014/05/P1010375_zps094b37a8-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010375_zps094b37a8.jpg.html)
I used a Dremel with the drum sander bit to make clearance for the wires. I was originally going to glue them in place with silicone. I came up with a much better idea. I used self-fusing silicone tape. It's waterproof like rubber and sticks to itself, yet can be removed at a later date for servicing.https://sl-i.net/FORUM/images/imported/2014/05/P1010374_zpsef181e8e-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010374_zpsef181e8e.jpg.html)https://sl-i.net/FORUM/images/imported/2014/05/P1010404_zps94ad0598-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010404_zps94ad0598.jpg.html)
Below is a picture of the cutoff. The adjustment screws work just as they had before. I am able to precisely aim the lights up/down/side to side.https://sl-i.net/FORUM/images/imported/2014/05/P1010385_zps9771078a-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010385_zps9771078a.jpg.html)
https://sl-i.net/FORUM/images/imported/2014/05/P1010395_zps2c56ea2d-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010395_zps2c56ea2d.jpg.html)
https://sl-i.net/FORUM/images/imported/2014/05/P1010400_zps5eff3401-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010400_zps5eff3401.jpg.html)
I need to experiment with my camera. I'm going to try manual settings. These were taken on full auto.
The projectors are Bi Xenon, (high and low beam) coupled with the JDMs factory high beams=Double high beams! They are a sight to behold. The photos don't do them justice.
Update: I have since replaced the factory high beam bulbs with Osram Nightbreaker Plus Unlimited and re-aimed the high-beams. I would like to take some "truer" photos, (in manual mode, not full auto).
I thought briefly about angel eyes... No
I thought about blacking out the reflectors... No
They are just not me. I prefer the clean look.https://sl-i.net/FORUM/images/imported/2014/05/P1010407_zps48bb688e-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010407_zps48bb688e.jpg.html)https://sl-i.net/FORUM/images/imported/2014/05/P1010406_zps8e6dd1f2-1.jpg (http://s472.photobucket.com/user/smstavros/media/96%20Subaru%20Legacy%20JDM%20Projector%20Headlight%20Details/P1010406_zps8e6dd1f2.jpg.html)