Hella 90mm HID capsule mounting in stock popups
 

Copied from my post on honda-tech about my LS1 FD conversion. Just letting people know that Hella's 90mm HID capsules WILL work with the rx7's popups.

HID installation pics. I only got one put in so far.

First things first. Went to visit the LS1 that morning to pull the wiring harness off. But I left my toolset in the rx7, so I couldn't take off a few of the wires.
http://kitsunedev.com/stuff/fd_hid_1/IMG_0138.JPG

Sadly, no pictures as we were cutting the mounts. May's hair got all covered in white plastic dust. Anyway, here they are with the projector mounted in the old halogen base. I'm using the old base for adjustability, and using the adjusters that shipped with the HID module just to mount it to the plastic.
http://kitsunedev.com/stuff/fd_hid_1/IMG_0139.JPG
http://kitsunedev.com/stuff/fd_hid_1/IMG_0140.JPG

I ended up having to cut two squares out of the bottom of the fiberglass popup housing to fit the back of the projector. There's enough clearance there now for me to adjust the shit out of it. You can sort of see the holes in the first two pictures.
http://kitsunedev.com/stuff/fd_hid_1/IMG_0142.JPG
http://kitsunedev.com/stuff/fd_hid_1/IMG_0145.JPG
http://kitsunedev.com/stuff/fd_hid_1/IMG_0146.JPG
http://kitsunedev.com/stuff/fd_hid_1/IMG_0149.JPG

By then, it got late. So I used the high beams from the prelude to sort of help out.
http://kitsunedev.com/stuff/fd_hid_1/IMG_0148.JPG
http://kitsunedev.com/stuff/fd_hid_1/IMG_0151.JPG
As you can probably tell, this really fucking sucked.

Got the ballast and wiring harness all happily connected:
http://kitsunedev.com/stuff/fd_hid_1/IMG_0154.JPG
http://kitsunedev.com/stuff/fd_hid_1/IMG_0152.JPG

And then I blew a bulb.
http://kitsunedev.com/stuff/fd_hid_1/IMG_0161.JPG
http://kitsunedev.com/stuff/fd_hid_1/IMG_0157.JPG

But, I bought two of everything. So I took the bulb out of the other projector housing and mounted it in my already-finished housing. Got everything nice and put back together.
http://kitsunedev.com/stuff/fd_hid_1/IMG_0167.JPG
http://kitsunedev.com/stuff/fd_hid_1/IMG_0168.JPG
http://kitsunedev.com/stuff/fd_hid_1/IMG_0170.JPG
http://kitsunedev.com/stuff/fd_hid_1/IMG_0173.JPG

Yes, it's bright as hell.
http://kitsunedev.com/stuff/fd_hid_1/IMG_0175.JPG
http://kitsunedev.com/stuff/fd_hid_1/IMG_0174.JPG

Tomorrow I plan on mounting the other one. I already ordered another bulb. God I feel dumb about that :P

Are you going to put the factory lense over that when its all done? Looks kinda tacked together without it. Also, those arent bi-level HID's are they? So you have super bright or nothing right?

Looks like a sound project, something I may want to try in the future, I'll have to see how the completed setup looks before I make any final decisions -- policia can be funny folk when it comes to lighting mods around here.

~Kris

I'm not sure about what I'm going to do about making it look professional. I may just paint the chrome part flat black. They're low beam only, though.

They ARE, however, DOT legal. So cops can't hassle you.

Also, just to point this out. They're still chrome housings. They look bad now because of the plastic dust that's settled on them. I'm going to clean them out sometime.

looks functional how much did everthing end up costing you and where did you get the parts?

Functional? Yes. Very. Extremely.

Price? Way too damn much. Around $1000.

Where? rallylights.com. Shipping was stupidly fast. Faster than you can blow a 13b. I ordered them last wednesday night, they shipped thursday and arrived friday.

So you're leaving the stock housings without the lens?

Look at the pictures. The large circular thing IS the lens.

We understand that the Hella's are selfcontained with their own lense however we are referancing the lack of the factory lense for aestetics sake.

Ah. The factory lens has the halogen diffusing things on it that would wreck the nice beam pattern from the HIDs. For that reason I'm leaving them off. After I clean the dust off of them they should look nicer.

At the very least, I will be putting the black cover that goes around the stock headlight back on. I just can't find it at the moment.

Make a custom cover out of the stock black one. Shouldn't be too hard and if you make it work it will look really nice, ever think about a kit if you could keep the price down?

Oh, and that beam pattern is really nice lookin, nice cutoff.

Wow! That is pretty pricey!

Maybe you can use the stock lens while cutting a hole (according to the shape of the HID housing) into it. It might look a little better that way.

Stock BLACK cover?

Which cover are you referring to?

I have a few ideas about how to make it nicer though. And I may consider doing these for people, not sure though.

The clear one.

I am planning on doing something similar with the hella 90mms. But I am going to take out the stock headlight beam housing (the gray parts in your picture) and make the headlights sleepy. I've seen some 2nd gen with that, but no 3rd gens yet.

https://www.rx7club.com/showthread.p...ighlight=hella

Looks like someone else did it before me. Guess I'm not going to be selling my ghetto fab mounts :P

Anyway, I'm not sure about any sort of cover plate yet. I may end up making something out of plastruct or the like.

I had the idea of using the same hella 90mm bi-xenon. I was going to eliminate the stock headlight housing and find a way to put it in and have the sleepy eye look. Then I was going to use a Fog lamp to put in the out side, kinda like this
http://img265.imageshack.us/img265/9...y1small3lg.png

shouldnt prevent you from selling yours too. make them sleepy eyes or cheaper something.

I've been considering something like this. Does there appear to be room for two lights sitting side-by-side, similar to the FC setup that KungFuMonkey linked to?

-s-

Not sure if you could fit two 90mm modules next to each other. You could, however, fit a 90mm low beam and a fog light or something for the high beam. I'm looking into what would be a good solution for a high beam, as I currently have none.

I'm pretty sure something like this would fit, but I'm not sure about light output.

Oh well, I have plenty of time before my rx7 will be running at all anyway.

And yes, these are quite tempting. But I don't feel like spending $600 for HID high beams...

^ those are nice. I go for those. but using HID's as a hi beam (unless you have the Bi-Xenon) is kind of hard. You have to wait for the light output to come on fully. Here is the thread on how to get that "sleepy" look
https://www.rx7club.com/interior-exterior-audio-26/how-sleepy-headlights-3rd-gen-351136/

"those" being the optilux 1000s?

Also, in reference to your username...my daily driver is a honda :P

It was pretty much the first thing it came up in my head as for a user name. But my Daily is a RX-8 looking into buying a 4 door integra for the wife

Hondas are slow. It's true.

Anyway, did you mean the optilux 1000s or the 50mm HIDs?

I would be all over a set of sleepy eye HIDs! Someone make them dammit!

Do it yourself. It's not hard :P

I might end up sleepying these. Not sure though.

Rotary Extreme was talking about making these... I just wish they put the low beam/projector on the outside.

http://www.rotaryextreme.com/dualbeam-1.jpg

Is a lot cheaper if you make it yourself. Is not hard either.
https://www.rx7club.com/showthread.p...59#post2809948

Oh and Philx that was the 50mm ones that I like

DAMN I LOOK GOOD :)

THANKS FOR THE PROPS, ^

:rlaugh::rlaugh::rlaugh:
:bigthumb: on the headlights, you should try sanding down the fluted lense and put em back on

Fluted lense is the chrome part?

I'm planning on cutting the front part off of the clear part so it hides the glue. Not sure what I'm going to do about the chrome. I may leave it, or paint it black.

Hmm, that's a thought and it's exactly what I'm looking for. I'm basically inept at this kind of stuff though. That's why I like the kit route:)

Received my fog lights which I'm going to be using as high beams the other day. As I figured, I have to remount the low beam in order to get the high beam to fit. Pictures gallery is here

Brand new cheapo fog lights:
http://kitsunedev.com/stuff/fd_hid_2/IMG_0405.JPG
http://kitsunedev.com/stuff/fd_hid_2/IMG_0409.JPG
http://kitsunedev.com/stuff/fd_hid_2/IMG_0411.JPG

Testing placement inside the housing to see where I'm going to have to mount the low beam:
http://kitsunedev.com/stuff/fd_hid_2/IMG_0416.JPG
http://kitsunedev.com/stuff/fd_hid_2/IMG_0417.JPG

So, I decided this would probably not be a whole lot of fun. So I decided to fall asleep. Then I came back the next day with May and pulled the cutoff shields from the inside of the fogs so they are actually high beams, not sideways low beams.
http://kitsunedev.com/stuff/fd_hid_2/IMG_0536.JPG
http://kitsunedev.com/stuff/fd_hid_2/IMG_0538.JPG
http://kitsunedev.com/stuff/fd_hid_2/IMG_0539.JPG

And then on sunday I completely destroyed the old mount to install the metal bracket for the low beam, and the bracket for the high beam. The low beam bracket is the square flat one with the hole in the middle.
http://kitsunedev.com/stuff/fd_hid_2/IMG_0568.JPG
http://kitsunedev.com/stuff/fd_hid_2/IMG_0572.JPG
http://kitsunedev.com/stuff/fd_hid_2/IMG_0576.JPG

This is the driver's side headlight. In the last picture, the bracket on the left is for the high beam. I'm waiting for the glue to completely cure before I mount the housings in it though.

Worked for a while on the headlight housings. The passenger's side housing now has the bracket for the high beam. I'm also working on reinforcing the driver's side housing.
Pictures.

Passenger housing:
http://www.kitsunedev.com/stuff/fd_hid_3/IMG_0589.JPG
http://www.kitsunedev.com/stuff/fd_hid_3/IMG_0592.JPG

Attached the front face of the driver's side housing. Then used zip ties to make sure the mounts weren't going anywhere. But then I thought that zip ties alone are kind of silly, especially in a headlight. So I covered them in adhesive. I plan to primer and paint the entire assembly before installing the headlights. It should be noted that the red zip ties are there only to hold the assembly together as the adhesive cures.
http://www.kitsunedev.com/stuff/fd_hid_3/IMG_0593.JPG
http://www.kitsunedev.com/stuff/fd_hid_3/IMG_0595.JPG
http://www.kitsunedev.com/stuff/fd_hid_3/IMG_0599.JPG
http://www.kitsunedev.com/stuff/fd_hid_3/IMG_0600.JPG
http://www.kitsunedev.com/stuff/fd_hid_3/IMG_0602.JPG

Not sure about what color to paint them. I'm thinking of just painting the whole thing metallic black, so it kind of blends in with the fiberglass bucket.

So what do you guys think would be better, the 50mm or the 90mm hella HIDs?
It seems like the 50mm would be easier to work with considering the space allowed.

The 50mm aren't out yet as low beams :D

Since they are about the same price why don't people use the 90mm bi-xenon, instead of buying a seperate fog light for the high beams ?

The bi-xenons wouldn't fit inside the rx7's popups. Otherwise I would've used those.

Oh, I thought that there were 90mm bi-xenons and 90mm low beams from Hella. So either way the conversion will cost around $1100 or am I looking at the wrong projectors ?

Hella makes both 90mm bi-xenon capsules and 90mm low beam capsules. I can't remember the reason exactly, but I believe that the bi-xenons were too deep to fit inside the housings. They're about the same price. Yes, they'll cost around $1000. I got mine from Susquehana motorsports, The guy there is very helpful and I got my HID equipment in the mail within 48 hours of ordering. If I were to order another set of them, I'd definitely go with them.

Also, it should be noted that if you order the replacement parts for the HIDs, instead of ordering the preassmbled new ones, you save $100-$200. If you email them, they'll explain it to you.

Also, if you're going to install them into your stock headlights, I can get more pictures of my mount setup. My high beams are the optilux (sp?) 1000s with the cutoff shields removed. They're simply screwed in, so you can remove them by disassembling the housing and unscrewing them.

Test fitted the projector and high beam into the housing and into the car today. I decided to test the housing in the car before I painted it so I don't mess the paint up if it doesn't fit. Good thing I did :P

Pictures here.

First, when I tried to fit the high beam module in, it wouldn't fit. So I trimmed the side of the low beam mount to make space:
http://kitsunedev.com/stuff/fd_hid_4/IMG_0716.JPG

For reference, here's what the bracket looked like before:
http://kitsunedev.com/stuff/fd_hid_4/IMG_0717.JPG

Got everything in fine after that:
http://kitsunedev.com/stuff/fd_hid_4/IMG_0718.JPG
http://kitsunedev.com/stuff/fd_hid_4/IMG_0723.JPG
http://kitsunedev.com/stuff/fd_hid_4/IMG_0722.JPG

Ended up having to trim a little bit off of the bottom of the fiberglass bucket to make room for the back of the HID capsule. These things are huge.
http://kitsunedev.com/stuff/fd_hid_4/IMG_0725.JPG
http://kitsunedev.com/stuff/fd_hid_4/IMG_0724.JPG
http://kitsunedev.com/stuff/fd_hid_4/IMG_0727.JPG

So I happily run over to the car to fit this thing in, and this asshole gets in the way:
http://kitsunedev.com/stuff/fd_hid_4/IMG_0732.JPG

Turns out it's scraping the side of the base of the projector. Like I said, they're huge. So I trimmed a bit off the edge of it to try to make it fit.
http://kitsunedev.com/stuff/fd_hid_4/IMG_0730.JPG
http://kitsunedev.com/stuff/fd_hid_4/IMG_0731.JPG

Well, that didn't work. I'd have to cut the entire side off it for it to fit. So I cut the thing off instead. From what I can tell, it prevents the headlight from going up too much. So I cut off enough to make clearance, but if the arm connecting to the motor fails, it would still intercept the headlight and prevent it from flying back. I need to apply some sort of rust protectant to it though. It kind of worries me having the metal exposed on it like that.
http://kitsunedev.com/stuff/fd_hid_4/IMG_0734.JPG

Anyways, so then I had clearance to mount the fg bucket and projector assembly, which I did. It works perfectly.
http://kitsunedev.com/stuff/fd_hid_4/IMG_0733.JPG
http://kitsunedev.com/stuff/fd_hid_4/IMG_0735.JPG
http://kitsunedev.com/stuff/fd_hid_4/IMG_0736.JPG
http://kitsunedev.com/stuff/fd_hid_4/IMG_0737.JPG
http://kitsunedev.com/stuff/fd_hid_4/IMG_0740.JPG
http://kitsunedev.com/stuff/fd_hid_4/IMG_0742.JPG
http://kitsunedev.com/stuff/fd_hid_4/IMG_0743.JPG

Pictures with the headlight retracted. The top of the headlight isn't aligned properly. It's a pain in the ass to do, and I'm not going to do it until I install these for the last time. I still have to remove them and paint them.
http://kitsunedev.com/stuff/fd_hid_4/IMG_0744.JPG
http://kitsunedev.com/stuff/fd_hid_4/IMG_0747.JPG
http://kitsunedev.com/stuff/fd_hid_4/IMG_0748.JPG

While I was working, the mailman came and delivered my new set of adjusters. Sucks that I had to pay $13 because I lost one of these:
http://kitsunedev.com/stuff/fd_hid_4/IMG_0751.JPG
http://kitsunedev.com/stuff/fd_hid_4/IMG_0749.JPG

Anyway, I need a good primer that works on both metal and plastic. And I also need a rust prevention thing. Not sure where to get them. And I'm way too lazy to go look now.