So I bought an old Rotary Extreme HID headlight kit recently and am about to complete the install, however noticed that the lights are closer to 4000k so doesn't match up with the rest of my lighting so I ordered some Morimoto D2S bulbs to replace the bulbs.

That's when I realized the bulb and base were modified to fit in a Hella 90mm halogen projector (68137). The D2S bulb is actually soldered into a H9 Hella projector base that screws out. I have no idea how I would replace the bulb now. It seems I'd either have to fabricate a new base to accept an actual D2S bulb or buy Hella 68139 true HID projectors (without the bulbs or ballast), but that'll set me back $300+ on top of the cost of the lights.

To anyone out there with experience with this kit, did you ever replace the HID bulbs and how did you do it?

 

Anyone?

Now I understand why Chuck would say you couldn't swap bulbs and you'd have to send the kit back to him for him to modify your kit. It's because he used the H9 halogen housing for the low beam even for the HID sets he sold and ghetto rigged them to fit a DS2 capsule by widening the hole and soldering the capsule permanently in.

After researching, I think I have a few options:

1) Fabricate a new projector backing plate to fit a DS2 bulb, which is pretty common in the world of Hella 90mm retrofitting.
See this link for an example: Archive Automotive Lighting Forum: page with H9 vs D2S bulb measurements? Also Hella 90mm

2) Buy another set of Hella classic 90mm low beam projectors and cannibalize the backing plates. While they are H9, at least they are cheap at only $55 each as opposed to $172 for the HID version (projector housing only)

3) Buy what was supposed to be in the kit in the first place - an actual set of Hella HL68139 HID projectors. They are still expensive at $477 each though!

I think I'm going to go with option 2. I can either modify the H9 fitting to accept a DS2 bulb or just get HID H9 capsules and new ballasts.

 

Why not replace it with some real HID projector? You got any picture of the projector and housing?

 

You mean like retrofit an OEM projector in there? I could do that, but I'm on a budget and don't want to go down an unbeaten path. I'd have to figure out how to fab up a mount and all that. It'd probably be cheaper than buying the Hella 68149 HID housing probably. I have to admit I like the look of the Hellas though.

I'll take some pics later and post them up.

 

Mounting a projector in these light should be fairly simple, and there are lots of good quality HID projector for under $150.