-Preheat oven between 290 and 350o
-Place sheet of acrylic in your frame and remove the bottom protective covering.
-place in oven ( i would suggest elevating it with something to keep the acrylic from sagging on the the oven rack.
-let it heat for 5-7mins. (until the center of the acrylic sags at least 3-4"
-turn your vacuum on
-remove frame from oven and immediately place over the assembly. make sure the frame is completely sealed against the table so you can get decent suction (no jokes please)
*for a better draw while vacuforming remove the lens from the projector
turn vac off, and let you mold cool. at this point, if you picked up the the acrylic the assembly will come with it. take your dremel and carefully cut around the out perimeter of the reflector. i cut about 1/8" more so that that acrylic can snap on the reflector, eliminating the use of glue. but i still used alitlle.
once you're done cutting, it should look like this
painted
fitment
ok time to add alittle subtle accents
drain stoppers purchaced @ target
cut the out rim
with alittle goop attach it to the assembly
Close it up
-take your nissan sealant (rubber butyle), stretch and place into the groove of the housing.
-you should be able to get 2 headlights out of 1 roll.
-Carefully pop the entire projector assembly back into the housing
*with the vacuform shroud, you will need to trim away the fin on the turn sig reflector for everything to go back together work properly
-take your oem headlght sealer and place around headlight
-place lens onto the housing and clamp down just enough to ensure a good seal be careful not break the lens.
-heat entire housing with a heat gun, and let it sit over night
-take the rear gasket and cut to size, and re-install.
*if you're using a bixenon projector you will need to put a small hole in the back of the headlight to run the wires out, i would use a grommet to ensure that it is sealed.
here is the finished product
night shots with 800k bulbs. (that was all i ahd at the time)
How to aim you new retros
follow these steps
1. park on level ground, 25 feet from a wall
2. measure the height from the ground to the center of the headlight projector.
3. then measure that same distance up at the wall and make a mark.
4. the lower cutoff should shine 2-3inch below that mark.
disclaimer
try this at your own risk. i am not responsible for any mishaps.
this was a general how to for retro-fitting. depending on the projector, and other circumstances some steps will differ.
hope to see some of you try this out
