rotary extreme sleek headlights
06-17-05, 11:07 AM
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rotary extreme sleek headlights
has anyone done the hid rotary extreme sleek headlight kit install.how easy was it and what was involved as regards the wiring needed for hid.really keen on kit but worried about
a/wiring
b/cutting frame
any install info wld be great..thks from uk
a/wiring
b/cutting frame
any install info wld be great..thks from uk
06-17-05, 11:10 AM
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installation instructions, framce cutting, and wiring all discussed here:
http://www.rotaryextreme.com/fdindex.html, then go to sleek headlight kit, then click on installation. However:
Rotary Extreme Sleek Headlight Kit Installation:
Thank you for purchasing the Rotary Extreme headlight kit for the 93+ RX-7. With proper installation and proper headlight adjustment, you should find the light kit to be the best and most affordable on the market today. If you have any installation questions, please email rotaryextreme@aol.com for support.
Warning:
Please wear eye protection goggle and mechanic gloves when installing the light kit. The brackets are sharp. Please handle with care.
Caution:
Please read this installation page completely before you attempt the installation.
Tools you will need:
Socket wrench (metric size with at least 10mm, 11mm, and 12mm sockets), wrench (metric size, 10mm, 11mm, 12mm), screw drivers, wire cramping tool, drill, drill bits (1/4"), and cutting wheel, touch up paint.
Hardware you will need:
14 gauge wires, butt connector, wire tap slice, 3M acrylic double sided molding tape, and silicone sealant, permanent marker or white out. Relay with 30A fuse if you wish to turn on both high beam and low beam while the light switch is at the high beam position.
Painting the housings:
On the headlight housings, please paint the base black to make it less visible. Once the headlights are put on, most of the base will be covered by the headlight assembly.
Cutting the frame:
1. Take out the stock headlight system. Please refer to the shop manual for details.
2. The installation requires cutting the frame. Please refer to the photo here:
Use the top part of the light mounting bracket as a template. Trace the edges of the mounting bracket using either permanent marker, whiteout or masking tape onto the frame and cut the frame accordingly. Use touch up paint on all the bare metal to prevent rust.
Headlight assembly:
3. Assemble the light mounting bracket assembly as shown below:
Test fit the brackets on the car and make sure the brackets are not interfering with any wires or the frame. The top part of the mounting assembly mounts onto the frame using the stock headlight mounting holes (circled in the photo below).
You might have to drill more holes on the top part of the mounting bracket during the final headlight adjustment. You will have to mount the low beam projector as closely as possible toward the center line of the headlight housing. Just keep this in mind at this point.
4. Unbolt the headlight mounting brackets from the frame. Assemble the lights onto the mounting brackets. The kit comes with 12 springs and 12 adjustment bolts.
5. First, assemble the high beam (brown light housing) onto the mounting bracket using the 2.5" bolts and spring.. Each light takes 3 springs and 3 bolts. The spring will have to be sandwiched between two washers. Use another washer on the back of the bracket where the nut screws into the bolts.
Mount the adjustment bolts the same way on all 3 corners. Screw the bolts in until the light bulb connector is on the opposite side of the headlight housings. Try the connector on to make sure the connector will clear the bracket.
6. Follow the same procedure for the projector low beam. Screw in just enough for the bolt to be flush with the nylon locknut.
7. Mount the headlight assembly onto the chassis.
Note: The photos above show the bracket for the low beam HID. For regular Halogen light kit, use the stock mounting points.
Headlight Wiring:
The stock headlight connector has 3 wires consisted of two red wires and one black wire. The bottom red wire is for low beam. The left hand side red wire is for high beam and the right hand side black wire is for ground. You can either splice the wires or cut off the connector and use butt connector to extend the wires to the Hella H9 connectors provided. Please make sure the wires are long enough to reach the headlight assembly. Connect both ground part of the Hella H9 connectors to the stock headlight ground wire (black) and +12V wires on the Hella H9 connectors to the separate red wires on the stock connector wire. Make sure you mark which H9 connector is for high beam and which one is for low beam.
If you wish to turn on both high beam and low beam while the light switch is at the high beam position, you will have to run an additional relay with a 30A fuse. You should be able to find a relay kit at your local auto parts store. The relay kit for the fuel pump also works in this application. On the relay, there are 4 terminals:
Battery +
Ground
+12V signal source
+12V output
You will need to hook up the relay to only one side of the headlight wiring unless you are running a high voltage light bulb. If you don't want to take the risk of overloading the wiring, you can install relays on both sides of the headlight wiring.
Connect the Battery+ and Ground terminals to the battery. It's easier if you do this on the driver side of the headlight kit since the battery is near by.
Splice the +12V signal source terminal to the high beam red wire on the stock headlight connector.
Use a 3 way butt connector to connect the +12V output terminal to the low beam H9 +12V wire.
Make sure you put the 30A fuse to somewhere you can easily access.
Connect the H9 connectors to the respective Hella 90mm lights and switch on the headlights to see if they work accordingly.
Light adjustment and housing mounting:
1. Verify if the low beam projector is positioning as closely as possible toward the center line of the housings. If not, you will have to drill new holes on the top of the light mounting bracket and move the light assembly toward the center more. By positioning the low beam projector toward the center as closely as possible, you will have a wider spread of light beam, hence providing better peripheral lighting.
2. Park the car on a level ground and 25 ft from a flat wall. Mount the headlight assembly on the car. Put the housings brackets onto the housings.
Warning: Do not mount the housings permanently on the car until light adjustment is done.
3. Measure the distance from the ground to the center of the low beam projector.
4. Place a piece of tape on the wall at the same height as the center of the lamp.
5. Turn on the low beam. Adjust the lights until the bright horizontal line of the light at the upper edge of the beam pattern is just below the tape on the wall.
6. Do the same for the high beam but the hot spot should be at the same height as the distance between the ground and the center of the high beam.
7. Try to put on the Lexan covers to see if the lights are back enough for the Lexan covers to clear. If the lights are sitting too much forward, please adjust accordingly and repeat 2-6. Please position the low beam projector as forward as possible. This will provide better lighting.
8. When pre-fitting of everything is ok, you can start to mark the holes on the chassis where the side bracket on the housings should be on. You should secure the side mounting bracket on the chassis first using the provided 1/4-20 bolts and locknuts and then secure the light housings onto the bracket. This way, you do not have to remove the bumper. Use the stock 6mm bolts to secure the top light mounting bracket.
9. Do the final adjustment. Do not put on the Lexan Covers permanently yet.
10. Put the 3M acrylic double sided molding tape on the Lexan Covers. Clean the housings with rubbing alcohol. Close the hood and then put on the cover while the hood is closed so you can make sure the covers will not interfere with the hood. Press firmly around the edge of the Lexan covers to make sure the covers are secured onto the housings. Please put the Lexan covers as forward as possible. If the trim at the front edge of the cover is blocking the light beam, you are not putting them on correctly. After the covers are secured onto the housings, you can also use silicone sealant to fill up the gaps between the covers and the housings. You can also use self tap screws to secure the Lexan covers.
11. Turn on your lights to make sure everything is in working order. Check the light beams to see if there is any final adjustment needs to be done. Adjustment of the light beams is the key to the performance of this light kit and it has to be very accurate. Please be patient.
12. Congratulations! You have finished installing the Rotary Extreme Sleeklight Kit.
http://www.rotaryextreme.com/fdindex.html, then go to sleek headlight kit, then click on installation. However:
Rotary Extreme Sleek Headlight Kit Installation:
Thank you for purchasing the Rotary Extreme headlight kit for the 93+ RX-7. With proper installation and proper headlight adjustment, you should find the light kit to be the best and most affordable on the market today. If you have any installation questions, please email rotaryextreme@aol.com for support.
Warning:
Please wear eye protection goggle and mechanic gloves when installing the light kit. The brackets are sharp. Please handle with care.
Caution:
Please read this installation page completely before you attempt the installation.
Tools you will need:
Socket wrench (metric size with at least 10mm, 11mm, and 12mm sockets), wrench (metric size, 10mm, 11mm, 12mm), screw drivers, wire cramping tool, drill, drill bits (1/4"), and cutting wheel, touch up paint.
Hardware you will need:
14 gauge wires, butt connector, wire tap slice, 3M acrylic double sided molding tape, and silicone sealant, permanent marker or white out. Relay with 30A fuse if you wish to turn on both high beam and low beam while the light switch is at the high beam position.
Painting the housings:
On the headlight housings, please paint the base black to make it less visible. Once the headlights are put on, most of the base will be covered by the headlight assembly.
Cutting the frame:
1. Take out the stock headlight system. Please refer to the shop manual for details.
2. The installation requires cutting the frame. Please refer to the photo here:
Use the top part of the light mounting bracket as a template. Trace the edges of the mounting bracket using either permanent marker, whiteout or masking tape onto the frame and cut the frame accordingly. Use touch up paint on all the bare metal to prevent rust.
Headlight assembly:
3. Assemble the light mounting bracket assembly as shown below:
Test fit the brackets on the car and make sure the brackets are not interfering with any wires or the frame. The top part of the mounting assembly mounts onto the frame using the stock headlight mounting holes (circled in the photo below).
You might have to drill more holes on the top part of the mounting bracket during the final headlight adjustment. You will have to mount the low beam projector as closely as possible toward the center line of the headlight housing. Just keep this in mind at this point.
4. Unbolt the headlight mounting brackets from the frame. Assemble the lights onto the mounting brackets. The kit comes with 12 springs and 12 adjustment bolts.
5. First, assemble the high beam (brown light housing) onto the mounting bracket using the 2.5" bolts and spring.. Each light takes 3 springs and 3 bolts. The spring will have to be sandwiched between two washers. Use another washer on the back of the bracket where the nut screws into the bolts.
Mount the adjustment bolts the same way on all 3 corners. Screw the bolts in until the light bulb connector is on the opposite side of the headlight housings. Try the connector on to make sure the connector will clear the bracket.
6. Follow the same procedure for the projector low beam. Screw in just enough for the bolt to be flush with the nylon locknut.
7. Mount the headlight assembly onto the chassis.
Note: The photos above show the bracket for the low beam HID. For regular Halogen light kit, use the stock mounting points.
Headlight Wiring:
The stock headlight connector has 3 wires consisted of two red wires and one black wire. The bottom red wire is for low beam. The left hand side red wire is for high beam and the right hand side black wire is for ground. You can either splice the wires or cut off the connector and use butt connector to extend the wires to the Hella H9 connectors provided. Please make sure the wires are long enough to reach the headlight assembly. Connect both ground part of the Hella H9 connectors to the stock headlight ground wire (black) and +12V wires on the Hella H9 connectors to the separate red wires on the stock connector wire. Make sure you mark which H9 connector is for high beam and which one is for low beam.
If you wish to turn on both high beam and low beam while the light switch is at the high beam position, you will have to run an additional relay with a 30A fuse. You should be able to find a relay kit at your local auto parts store. The relay kit for the fuel pump also works in this application. On the relay, there are 4 terminals:
Battery +
Ground
+12V signal source
+12V output
You will need to hook up the relay to only one side of the headlight wiring unless you are running a high voltage light bulb. If you don't want to take the risk of overloading the wiring, you can install relays on both sides of the headlight wiring.
Connect the Battery+ and Ground terminals to the battery. It's easier if you do this on the driver side of the headlight kit since the battery is near by.
Splice the +12V signal source terminal to the high beam red wire on the stock headlight connector.
Use a 3 way butt connector to connect the +12V output terminal to the low beam H9 +12V wire.
Make sure you put the 30A fuse to somewhere you can easily access.
Connect the H9 connectors to the respective Hella 90mm lights and switch on the headlights to see if they work accordingly.
Light adjustment and housing mounting:
1. Verify if the low beam projector is positioning as closely as possible toward the center line of the housings. If not, you will have to drill new holes on the top of the light mounting bracket and move the light assembly toward the center more. By positioning the low beam projector toward the center as closely as possible, you will have a wider spread of light beam, hence providing better peripheral lighting.
2. Park the car on a level ground and 25 ft from a flat wall. Mount the headlight assembly on the car. Put the housings brackets onto the housings.
Warning: Do not mount the housings permanently on the car until light adjustment is done.
3. Measure the distance from the ground to the center of the low beam projector.
4. Place a piece of tape on the wall at the same height as the center of the lamp.
5. Turn on the low beam. Adjust the lights until the bright horizontal line of the light at the upper edge of the beam pattern is just below the tape on the wall.
6. Do the same for the high beam but the hot spot should be at the same height as the distance between the ground and the center of the high beam.
7. Try to put on the Lexan covers to see if the lights are back enough for the Lexan covers to clear. If the lights are sitting too much forward, please adjust accordingly and repeat 2-6. Please position the low beam projector as forward as possible. This will provide better lighting.
8. When pre-fitting of everything is ok, you can start to mark the holes on the chassis where the side bracket on the housings should be on. You should secure the side mounting bracket on the chassis first using the provided 1/4-20 bolts and locknuts and then secure the light housings onto the bracket. This way, you do not have to remove the bumper. Use the stock 6mm bolts to secure the top light mounting bracket.
9. Do the final adjustment. Do not put on the Lexan Covers permanently yet.
10. Put the 3M acrylic double sided molding tape on the Lexan Covers. Clean the housings with rubbing alcohol. Close the hood and then put on the cover while the hood is closed so you can make sure the covers will not interfere with the hood. Press firmly around the edge of the Lexan covers to make sure the covers are secured onto the housings. Please put the Lexan covers as forward as possible. If the trim at the front edge of the cover is blocking the light beam, you are not putting them on correctly. After the covers are secured onto the housings, you can also use silicone sealant to fill up the gaps between the covers and the housings. You can also use self tap screws to secure the Lexan covers.
11. Turn on your lights to make sure everything is in working order. Check the light beams to see if there is any final adjustment needs to be done. Adjustment of the light beams is the key to the performance of this light kit and it has to be very accurate. Please be patient.
12. Congratulations! You have finished installing the Rotary Extreme Sleeklight Kit.
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