I am about to retrofit my factory Headlight with a Projector from Retorofitsource.com.
The VMAX factory headlight isn't the best as many have found and a projector will fix that.

I ordered the kit from retrofit source.com and its on its way here. I should have it next week

I started this new thread to capture info from start to finish as I attempt this project.

Couple of links where other useful threads on the same subject capture some good information:

www.starvmax.com/forum/installed-mods/12...projector-hid#121007

www.starvmax.com/forum/installed-mods/128249-my-morimoto-mod

www.starvmax.com/forum/19-how-tos-and-ge...d-kit-install#119790

I got a spare headlight from a friend (Thank you Tom) to learn on before I attempt this on my own headlight
Tonight I opened up the Guinea pig headlight (might want to look away now Tom )

This is the part I was most nervous about, but I am sure there will be more challenging bits coming up
I wanted to paint the inside of the headlight black as the factory reflector is redundant now, but this is proving to be more difficult than I thought. I am now thinking I might not do the painting as it requires the removal of the lens itself to expose the chrome reflective bits so it can be masked properly. Not sure if I can re-attech the lens without it coming lose with vibration as the factory bond was strong

Here are some pictures of me breaking into the guinea pig headlight.

As you can see in the below photo the lens itself is held in place with nothing bust some super strong factory glue.
I am afraid if I separate the lens itself on my bike's headlight and re-attach it with just glue, that through time with vibration and exposure the bond might not be as strong as from factory and the lens might come off

On the other hand I can't really get this mod done the way I really wanted to get it done by blacking out the internals unless I do this. Decisions, decisions

Good thread Kris! Hoping to make this my next winter project. I have an HID light already but the beam and spread are definitely not the best.....

VMaxChuck wrote:
Thanks Chuck.
I am in the same boat as you. The HID bulb inside the factory headlight is one of the first mods I ever did some 3 years ago. But as I am sure you already know that the reflectors don't work well in reflecting the HID beam and while you get that blue tinge and a cool look, you actually don't gain any visibility on the road. You lose it! Which is why I am doing it properly now

My search for the ultimate VMAX!

Today's job was to man up and tear into my own bike's headlight

Getting the light of the bike was easy and then the nerves started to kick in
Put it into the own and wait for 7-10 minutes. FInally the timer went off and I didn't melt the darn thing

I then separated the back housing from the front chrome housing.
This was quicker second time around and happy to say I did a darn good job at it with no dints in the housing thanks to my practice headlight.

The last step was to separate the actual lens from the housing like before and this thankfully worked well as well.

At this point I noticed that my front lens was in a pretty bad shape from all the chips and stones.
I mean I did buy to ride the darn thing and after 3.5 years it took some beating

So as you do I went to town inn the lens with sandpaper and my Makita polisher
Sandpaper 400, 800, 1200, 1500 and the polish it up
It turned out okay I think. No chips any more and it looks like a pretty new lens now

I then went ahead and masked up everything for the painting since I decided to black out some bits
This was little nerve wrecking as I am not great at paining. Decided what to keep chrome and what to paint and went ahead
I also choose to paint one of the reflectors black as I don't know how much of that will be visible so I will decide to go full black or leave the reflector chrome once the kit arrives

After all the painting and polishing I married the lens back with the housing waiting for the next step
This is the hardest part done I hope. Electrical stuff doesn't worry me, but painting makes me nervous

Now just have to wait for my Retrofit kit to arrive
Till next time

Looking Good Kris nice to add your own flair to the job what are you using for epoxy/glue/mastic for the lens to reattach it
reason i ask is some glues will craze plastic or make it milky around the joint .

know you dont have your kit yet but the trim ring that slips over the intensifier has a flat side i chose the bottom for that but some chose the top and mine was not fitting so good in fact i had to sand the inside edge just a bit to get it to fit but others did not but in retrospect i might have heated it just a bit when i fitted it together, Hopefully yours will slip right on.

I used Loctite Professional Super Glue. You can get it at your local walmart I would think.
You have to make sure that the chrome bits that are left unpainted don't have any dirt, contamination fingerprints, etc ... otherwise glue vapours will stick to that and make it very visible and ugly



Not sure I am following your other tip, but I am sure it will make sense when I get my kit

Hey Bob/Johnnie/Joey/Lucas,

When you fitted the projector inside the reflector, did you have to cut the reflector hole to make it bigger so the projector fits?
No one seemed to have documented this part on their VMAX install which is making me think this might me a hard part.
How did you work out how far back to set the projector?
Did you have to cut the shroud to make it fit inside the headlight? Or allow enough rotational movement for adjstment?
Did you have to epoxy the projector to the reflector or do the nuts hold it tight enough through the reflector hole?

Nice and interesting project Kris.
I am a little concerned with you choice of sealant for the lenses. You need to make sure that you get a nice water tight seal otherwise you will get moisture in behind the lenses.

I have used this product in the past www.fixtech.com.au/process/catalogue/ite...=3145&categoryId=574 with great success.

With CA adhesive you need to make sure that they do not become brittle with UV and heat from the lamp.

Thanks for the tip Nick.
Surprisingly enough, the seal from factory wasn't silicone based either.
It seemed to be glued on there with some sort of super glue that goes solid state

I might put some more sealant around it to keep it protected from elements at the end
I don't think the heat will be the issue as its only a 35w bulb, which is less than factory 55w
Plus I already had it in the oven at 120c and it was no issue.