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Join in on this Discussion and see the pictures. Click here-> : HID install into winter beater


Manntis
05-12-2006, 01:56 PM
I ordered a set of replacement 4656 quad lamps from http://www.spitzkraft.com

http://www.rotorhead.ca/projects/hid1/02.jpg

They arrived well packed and undamaged.

http://www.rotorhead.ca/projects/hid1/03.jpg

The kit included all the wiring and hardware...

http://www.rotorhead.ca/projects/hid1/04.jpg

...and bulbs, which came pre-installed in the assemblies. I took this Philips D1S bulb out of the low beam housing so it could pose for this photo.

http://www.rotorhead.ca/projects/hid1/05.jpg

I started by swapping out the high-beams, since the new high beams were halogen and a snap-in replacement (sort of - more on that later)

http://www.rotorhead.ca/projects/hid1/06.jpg

The clear lens polycarbonate halogen replacement is about the same size as the old sealed beam unit, and comes with a harness adapter for plug-and-play electrics.

http://www.rotorhead.ca/projects/hid1/07.jpg

Will the new 4656s just pop in place of the old? Let's make sure...

http://www.rotorhead.ca/projects/hid1/08.jpg

Just release the spring...

http://www.rotorhead.ca/projects/hid1/09.jpg

..and tap the bucket out from the two aiming screws...

http://www.rotorhead.ca/projects/hid1/10.jpg

Oops! the Chrysler headlight buckets have a small opening at the back. It doesn't fit!

Manntis
05-12-2006, 01:57 PM
http://www.rotorhead.ca/projects/hid1/11.jpg

No worries, just trim out a bit of metal...

http://www.rotorhead.ca/projects/hid1/12.jpg

Much better!

http://www.rotorhead.ca/projects/hid1/13.jpg

now I just had to attach the harness adapter, and the high beams were done.

http://www.rotorhead.ca/projects/hid1/14.jpg

The low beam Xenons didn't fit either.

http://www.rotorhead.ca/projects/hid1/15.jpg

So more cutting...

http://www.rotorhead.ca/projects/hid1/16.jpg

And voila! Notice I left room for the harness adapter to stick through at the side, and taped it with vinyl tape to prevent the metal cutting into the wire insulation.

http://www.rotorhead.ca/projects/hid1/17.jpg

Fits like a glove. Now to mount the ballasts!

Manntis
05-12-2006, 01:58 PM
The Daytona features metal panels behind the lights that protect it the engine bay from front splashes, and these panels are further protected by overhangs. Because they're well forward of the engine, these front corner positions are also fairly cool, considering they're in an engine bay.

Electrics such as the ballasts are far happier in cool and dry positions such as this!

http://www.rotorhead.ca/projects/hid1/18.jpg

First, we have to make room on the driver's side. I took out the battery...

http://www.rotorhead.ca/projects/hid1/19.jpg

...then the coolant reservoir...

http://www.rotorhead.ca/projects/hid1/20.jpg

The ballasts will go in this corner. Eventually.

http://www.rotorhead.ca/projects/hid1/21.jpg

The air cooled computer and it's huge housing has to get out of the way.

http://www.rotorhead.ca/projects/hid1/22.jpg

A semi-hidden bolt. Oh, those wacky Chryco engineers!

http://www.rotorhead.ca/projects/hid1/23.jpg

Out she comes. This will make working on the front wall, and stringing the wiring harnesses, much easier.

http://www.rotorhead.ca/projects/hid1/24.jpg

With battery, tray, coolant bottle, and computer housing out of the way, there's tons of room to work.

http://www.rotorhead.ca/projects/hid1/25.jpg

Meanwhile, on the passenger side, all I had to do was drill holes and mount the ballast. I decided to do this side first, as it'll have harness running past the left side ballast later.

http://www.rotorhead.ca/projects/hid1/26.jpg

so far, so simple...

Manntis
05-12-2006, 02:00 PM
http://www.rotorhead.ca/projects/hid1/27.jpg

I ran the green wire, which plugs into the stock harness, and the bulb harness through a hole in the frame...

http://www.rotorhead.ca/projects/hid1/28.jpg

...and out beside the bulkhead.

http://www.rotorhead.ca/projects/hid1/29.jpg

D'OH! There's no reason for this sub-harness to be attached to the light assembly, since it just plugs into the stock harness at one end and to the green wire at the other. This means I didn't need to cut and vinyl-tape that side notch earlier.

Ah well. Live and learn.

http://www.rotorhead.ca/projects/hid1/30.jpg

I dunno if it's unique to Chrysler headlight bezels, but mine were an extremely tight fit. I cut out some of the rounded corner so I could put them on over the lights without scratching the polycarbonate lenses...

http://www.rotorhead.ca/projects/hid1/31.jpg

There! Snug like bug in rug.

http://www.rotorhead.ca/projects/hid1/32.jpg

Connected up the harnesses to the ballast...

http://www.rotorhead.ca/projects/hid1/33.jpg

I repeated my ballast and light mounting efforts on the left side. You can see I ran the right-side harness up along the front edge of the radiator. The metal was shaped just right to act as a full-length retaining bracket!

Manntis
05-12-2006, 02:01 PM
http://www.rotorhead.ca/projects/hid1/34.jpg

Putting the battery tray, computer housing, and coolant bottle back. You can just see the ballast beside and behind it. In the Daytona, there's about an inch and a half between the coolant bottle and the metal wall I mounted the ballast to, so the two don't touch.

http://www.rotorhead.ca/projects/hid1/35.jpg

Mounting the relays (I've since tidied up that harness overlapping the rear relay)

http://www.rotorhead.ca/projects/hid1/36.jpg

Each harness has two 20 amp fuses mounted in a fuse block, and a red (power) and black (ground) wire. The two blocks snap together to make a chain, seen to the left of the strut tower...

http://www.rotorhead.ca/projects/hid1/37.jpg

...and the red and black wires I bolted directly into the side battery terminals.

http://www.rotorhead.ca/projects/hid1/38.jpg

Well protected ballast (notice the overhang?)...

http://www.rotorhead.ca/projects/hid1/39.jpg

Clean install! Dirty beater car!

All wiring neatly tucked and secured, ballasts in cool, dry areas, relays and fuses safe and sound with their stock counterparts...

http://www.rotorhead.ca/projects/hid1/40.jpg

The new HID projectors stick out more than stock since they sit in the same buckets, but I think they look good.

http://www.rotorhead.ca/projects/hid1/41.jpg

Done!

Manntis
05-12-2006, 02:01 PM
http://www.rotorhead.ca/projects/hid1/45.jpg

a hasty shot, lights aren't aimed yet...

http://www.rotorhead.ca/projects/hid1/47.jpg

as seen from the front

Say No To Pistons
05-12-2006, 03:11 PM
you need a new beater lol.

Manntis
05-12-2006, 03:21 PM
you need a new beater lol.
Why? The whole point of a winter beater is to have a strong battery, effective coolant system, good winter tires, weight on the drive wheels, and good lighting.

The paint condition is incidental, since lazy people with all-season tires often slide into you and ding your car anyhow.

tnap
05-15-2006, 02:19 PM
Man that's an awesome write-up.
Can't believe all for a beater :D

psychoseven
06-17-2006, 06:59 PM
nice.

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