DIYish: 05' Zx-6r Projector Retrofit W/ Ccfl Angel Eyes In Progress - Pics!!! - Kawasaki ZX-6R.net

aavhidsystem · 05-22-2008, 03:22 PM

Hey guys.

One day while eating pizza and staring at the bike in the living room, I realize the 636 was a magnificent looking machine however something was lacking. Grabbing for another slice of pizza, my eyes caught a pair of Acura projector headlights that I originally planned to retrofit into my previous car which I sold awhile back. It dawned on me that the bike was lacking the aggressive look and a projector retrofit might be something to set it on the edge.

Don't get me wrong I retrofitted several headlights before but something told me to take my time with this projector - 3 weeks and counting (mainly because I needed to buy other parts so read on).

Since I had to remove couple fairing parts, I decided to pull all of them off. Since the bike was bare, I decided to purchase the Scorpio i600 (perimeter and remote ignition kill) and install it in the process.

To prepare myself for baking the 636's headlight, luckily I had the Acura's headlight to practice on. Basically preheat to 350 degrees and shut it off. Pop the headlights in for a good 5 minutes.

Prying off the lens was a rather tedious task which I found was the most difficult in this whole process. I had to use my strength but at the same time, be very delicate as to not "deform" the soft housing. After 10 or so minutes the lens are finally off!

Now begins the fun! Since the projectors had a wide base I had to trim the edges. Once the projectors were sized correctly, I ran into couple dilemmas. I had to find a way with to fit the projectors in the reflector housing but since the reflector did not sit flat due to the bottom curvature, it was rather difficult to bolt the projectors on and allign the cutoff to be completely horizontal. Basically I would have to mount the headlight back onto the bike and alligned from there which would be a pain. Luckily my dad came up with a wonderful solution.

We threw the idea of mounting the projector on the reflector housing and decided to mount the projectors directly to the exterior housing then I ran into another dilemma - adjustability. Twice my dad came to the rescue. We went to kmart and bought a set of 2.5 inch screws. We drilled a hole into the top corner of the projector base. Since there is an existing hole in the headlight housing we did not need to drill a hole. We slid the screw into the hole of the projector, put couple washers between the projector and headlight housing for the height and screw in the nut from the backside of the headlight. For added safety we added a locking washer so the nut doesn't come loose when riding. So now we had a pivot point. Instead of drilling a hole, we decided to make an "arm" that would connect the projector to the adjusting screw on the headlight. The arm is basically made of stainless steel metal. By drilling the hole bigger than the screw, that gave us some play for adjustability. This also solved the cutoff problem because by moving the pivot connection between the arm and projector up or down, it will slightly rotate the projector accordingly. Since we solved the issue of adjustability, it was smooth sailing from here.

Now that the projectors are mounted, I decided to test try the lens on to see how the finish product might look like. Enjoy!

The headlight sure look aggressive but it doesn't look complete. Since the reflector housing was gone, too much can be seen on the inside of the headlight. Another problem was that the projector look a little plain. To solve both problems, I had to paint the entire headlight interior (wire, bolts, etc) as well as the metal projector housing with hi temp black spray paint. To solve the plain look, it was off to ebay to find an aggressive looking shroud.

I purchased the Gatling Gun Shroud from the Retrofit Source from Matt. When it came, boy was I in for a surprise. It was too big! Pulled out my trusty dremel and started hacking away. I was surprise to see how much I had to cut for the shrouds to fit. Since the shrouds was for a 2.5inch projector and I have a 3", I had to cut the mounting tabs of the shrouds. So off to Lowes for some JB weld and crazy glue. Before applying the shroud onto the projectors, I spray painted the entire interior of the headlights as well as the metal projector body. After applying the adhesives, I left the headlight and shrouds alone for a little over 24 hours. Here is the finish product!

I got a little anxious to see the end result so I test fitted everything with the upper fairing and windscreen.

To be continue....

When the CCFL angel eyes arrive, I should be able to take couple more pics. Any comments would be great! If you have an advice I would appreciate them as well. Thanks!

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UPDATE 5/22

The CCFL Angel Eyes arrived today; ironically couple hours after I finished this tread.

Whatever you do, do not assume the measurement given by the seller of the shroud and then order the CCFL angel eyes like I did. Unfortunately and fortunately the angel eyes was couple milimeters smaller but it wasn't by much so adhering the angel eyes to the shroud was not a difficult task.

First I crazy glued the CCFL in place and similar to spot welding, I spot "JB" weld.

... and the front view.

Finally finished. DEFINITELY A MORE AGGRESSIVE LOOK!

BEFORE

AFTER

Different views:

CCFL ANGEL EYES ON!

THE WHOLE BALL OF WAX. XeBrite 55W 6000K HID KIT w/ CCFL ANGEL EYES.

Thank you all for your support. I hope you like the finished product. Any comments and criticisms are welcome.