VmaxOZ wrote:
No all that stuf is cut and dried no cutting involved at least not for mine did you get the angel eye one Kris ? I think Lucas
had some clearance issues with that cause it's larger ? but worked thru it no other epoxy except what we did to get the angle right on the cutoff and really that was more to hold it in place so it did not move during reassembly , Once you get the kit in hand it will become clear right now you are over thinking it, the hard part is the oven ritual , I question the superglue as well i would think something more of a seal as well that if need be could be taken back apart dont think superglue will seal either but then again i did not take my lens out so that is just from experience with watch crystals
plastics and superglue usually does not end well when customers would attempt to glue the popped out Crystals back in
but i am sure you were aware of the effect of that stuff on clear plastics too. Wonder what Yamaha uses and what method
did you use to remove the lens ? did the heat soften the glue ?

Once you get all the hardware on it stays put .

Not much heat in the globe part either the tube takes that .

I made sure the bond was stronger than factory. There is no way that lens is coming off. I did seal it with clear silicone after I put it all back together and water tested it to make sure there are no leaks. It's all good in that department. I tried it all on the guinea pig light and the tests passed.

Yes, the heat did help soften the glue to help the lens pop off. I used a thin blade to get inbetween and slowly separate it just like the main Housing. It was much easier than separating the main housing to be honest. You will see once you pop the lens off that the stuff they used wasn't all that great. Probably better sealed now than from factory

Just waiting now

Hi Kris,

enjoying watching your progress on this as I too do a lot of night rides with standard hid upgrade being my first mod 3.5yrs ago. Still wasnt happy with that, thought maybe due to the cheap import kit i purchased, so then shortly after upgraded and spent a lot more on the Philips kit hoping this would fix it.. and yeah you guessed it

So have pretty much just put up with it until this mod re-emerged.

Looking forward to your adventure and ever insightful right ups!

Oh yeah.. Did you happen to query Matt re using the 55w ballast over the 35 being a brighter option?

Cheers,

Chris

When I put mine back together I didn't use any additional "glue" I pre-heated the exiting factory glue and spread it out.. then just put it back together and put a clamp on it. I have had no problems... I have 4K on the Max since then and have ridden through several rains for miles and miles.

I must be missing it or something, but how do you get the lens out???

snf05 wrote:
Thanks Chris.
I will do my best to keep you guys informed as I go along.
CaptBob is right, I am over thinking it a bit as I with with all my mods. If you can't do it properly don't do it at all

I did write to Matt to have his view and basically its a personal preference I think
a 55w balast won't last as long as the 35w. 35w seem to be more reliable long term is the concensus.
A 35w balast with a 5000K bulb will be as bright as a 55w 4500K bulb for example
For most light you shouldn't go above 5000K really, but I opted for the 6000K as I wanted a bit of that blue tinge
I am sacrificing a bit of brightness of the look there

I will post a photo of the kit itself once it arrives.

Here is what I ordered from Retrofitsource.com

Products

---

1 x Pc: RHD Mini D2S Projector - THIS IS WHAT IS NEEDED FOR AUSTRALIA OR UK. FOR THE US YOU NEED LHD Projector
1 x Pc: 3Five D2S Long Cord Ballast
1 x Pc: H4 Cycle Relay Harness - motorcycle specific harness to allow both low and high beam
1 x Pc: 3Five D2S 6000K Bulb
1 x Pc: E46R Extended Shroud - you can chose your shroud option, but I went with what I knew works from the guys here

---

Sub-Total: $140.00
USPS Express Mail International: $53.83
Total: $193.83

So for a proper HID setup I think $200 bucks isn't bad.
My kit landed in Australia today and is waiting customs clearance as we speak
I should have it on Wednesday to start playing with it

Sgroves79 wrote:
After you bake your light in the oven you have to use a putty tool to get in-between the lens and chrome (what I call middle housing - between lens and black - back housing). And slowly pry it away one bit at a time. You don't need a lot of force or pressure for it to come apart. Its not sealed all that well from the looks of it as it came spare quite easy

Then you do what ever modding you want to do and seal it back
One idea I had was to cover the inside with Carbon fiber, but I though this might be more of a job for somebody around here that is known for their finer work :wink wink: (yeah you know who you are). So I settled for paint instead

Then I made sure I cleaned the chrome bits real well before sealing the lens back on there. If you have finger prints on there for example the fumes from the glue or sealant might grab onto the prints and it will look real bad so MAKE SURE YOU CLEAN IT WELL FIRST!!!

Then I re-sealed it with clear silicone just to make sure no water gets in.
And now waiting for the fun part to begin

Came home today to a package from retrofit source.com.
Which means only one thing, lets get back into it.

All the bits seemed to be here. Time will tell I suppose
It got here very quick. 4 business days to be exact which is very fast from the US

First impression of the products is good. seems like a nice piece of kit for $140.
A quick test fit inside the lens and it all seems to fit okay
I was glad I read up on this before I ordered as it is so easy to get the wrong size shroud for example
The balast is a little bulky for a bike I still think and I hope I can find a good place for it as the long chord isn't as long as I hoped

Here are some photos of the items that came in the package

First thing is first. Get all the tools and equipment required together.
As you know I've done some pre-work before my stuff arrived like polishing the front lens from all the beating it took over the years and also did some painting as I though that might look nice. Personal preference.
Neither of the above is really necessary, just me making it my own

Then I went to test fit all the bits and play with ideas in my head.
One idea was to fit another one of my abel eyes inside the headlight to go with my scoops.
But then I though that might be overkill and would take from the effect from the scoops
So I decided to do something different.

I had 2 factory reflectors available to me. One I painted black and the other I left factory
I decided to use the non painted one and fit an angel eye behind the projector facing the factory reflector to give it a nice glow
This of course presented its own challenges on routing the wires and drilling a small hole on the reflector to pass the wires through

Here you can see the hole I drilled in the reflector



When I test fitted the projector I noticed the high beam mechanism and how it operates.
This meant that you had to align it a certain way. In order to achieve that alignment I had to modify the H4 slots
WIthout trying to explain it my writing about it I'll let the picture explain it. You can see where I used the Dremel to widen the slots and that seemed to have worked



Below you can see where I mounted the angel eye (behind the projector facing the reflector) and how the projector itself fits inside the headlight housing







Here are a few photos with the shroud fitted over the projector

What for dinner honey? Mmm headlights? Well at least that explains the smell she says



Back in the oven for 7 minutes at 130C or 265F whichever you prefer and wait for that "Ding"
Apparently no need to worry all the components will be find in the oven

After 7 minutes got some gloves and screws ready to put it back together again
Before I squeezed the housings back together I re-distributed the glue in the front housing to make a good seal again
This only took about 1 minute and then I pressed them together as close as I could to make a good seal

Seemed to fit together well so I went ahead and secured the screws back in their place again to hold it all together followed by a clamping process until it cools down completely

Now the light is back in one piece again.
I was able to test the angel light and its working fine, but I didn't test the projector or the solenoid before I sealed it which is probably something I should have done.

Something that is dawning on me is weather or not I turned the projector the right way in the housing?
I didn't think much of it until now. I know I haven't turned it sideways which is good I guess, but I am not sure if its upside down or not. It better not be or I won't be happy

And here is the finished product