PontiacBonnevilleClub.com

I just bought one of these: http://cgi.ebay.com/NEW-10-HAND-RIVETER ... 3cb3383ad7

works great for a cheap tool!

Riveters are cheap at farm and fleet places too. We use ours quite a bit.

Nice S10 forsure!


Always wanted to see someone do the projectors on these trucks.... was curious as to what they looked like....

Well this is 99% done. Unfortunately the 1% is keeping it from lighting up! Turns out my ballasts are crap. I got in contact with Matt at The Retrofit Source and he rushed a new set of quality ballasts my way. Really got to give those guys props.

But other than not lighting up (lol) this retrofit is DONE!

These 6mm bolts are needed to attach the headlight bucket onto the truck. I got some extended bolts (6mm x 50mm) so I could bring the assembly out a bit for spacing. 50mm was a bit unnecessary though, I think I could have gotten away with 30 or 40mm.



First, it's time to modify the buckets...



As it turns out, it's only necessary to cut the 'wings' off of them for the projector to fit.



Projector in snugly.



Time to figure out how much I need to space the headlamp assembly away from the truck. For me, the magic number of washers for all mounting bolts was 10.



All mounted up...



Next it's time to seal these up...



I used aluminum tape wrapped in several layers to seal the holes around the back. Works great.

3M window weld works great to seal the lenses up front.



A thin line of it all around is all that is necessary...



All sealed up.



I found out much to my happiness that I didn't have to modify the grille at all even with the headlights extended outward. So, I just went ahead and put the grille back on and snapped some finished shots!













The lights don't stick out far at all...

Unfortunately as I mentioned earlier, they don't light up. At least not reliably, so no output shots yet. When one did fire up though the output looked great.

More Friday or Saturday when the ballasts arrive, or maybe some more shots of the truck outside of my driveway...
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Good work!!!

Thanks Ed!

Well I couldn't resist, and I just had to get some kind of output shot. So I managed to get one of them firing and took some shots of the low and high beam!

Remember this is just with ONE light working...

Low beam...



High beam...



I cannot wait until both are working.

By the way, my rotation isn't off, the driveway is just sloped to the left. Driving it up and down my street, the rotation seems to be absolutely perfect.
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Dang.... Come do that to my Bonneville...

Looking really good.... Can't wait to see them both working..

Could you paint the screws black? The ones that hold the lights in.

Thanks guys!

I'm not worried about the bolts lol...besides painting them black would only make them stand out more in an all-chrome housing.

Honestly though, are they even that visible?





I don't think so. Not unless a person got right down on the housing and looked, but who is really gonna do that?
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Hmmm, I guess im just not a fan of the projector look, no matter what vehicle it is. But clean job anyways!!!!

Yeah the look's not for everyone, thanks though. For me it's only a little about the look but mostly about performance!

Speaking of which, output shots...



I am especially happy about just how perfect it came out...neither projector is off rotationally by a single degree in relation to the other one...





These particular pictures don't really do the high and low beam justice, I'll have to try again later.
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That cutoff is absolutely amazing. Great work!!!!!

Wanna rig a set of projectors for me?

Thanks Ed!

Few more pics. Probably gonna have a few more over the next few days once it stops raining...







Also updated my sigpic for the occasion.
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Sweeeet!

Thanks Booze!

Here's some good shots of the high and low beam. This is what it looks like in person.





I got to flash someone for leaving their high beams on while coming towards me yesterday...that was fun.
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Now thats what I'm talkin 'bout

That looks and performs bada$$ from the pics. It's nice to see someone install HID's the right way. I hate seeing the endless threads on fullsize truck forums where people add HID's into stock housings with no projectors. No projectors on lifted truck with HID's and headlights that have not been re-aimed is common...and blinding. It is sad that so many people who install HID's fail to set them up right and don't care about blinding other people.

I wish I had that kind of light output on my truck. I had a deer give me a scare last night and more light would have helped.

Dan, I have your next mission: headlights that move with the steering.

Thanks for the comments guys, I appreciate them! Lol no moving projectors though Ed...I cannot even begin to imagine the nightmare of trying to get that to work D:

Alright, time to get serious with the picture taking now that the weather is calming down and I'm feeling a little better. My truck is very dirty right now, so please excuse that...

















Nice color along the cutoff...

There's a video too but I don't know if it's worth posting. I'll think about it.
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