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DIY Mini h1 (02-04)
This Comprehensive DIY Guide covers doing your own retrofit with Mini H1 bixenon projectors and full-size shrouds.
Time required: 6+ hours (estimated)
Tools/materials required:
- Dremel/rotary tool/ with cutoff wheel and grinding stone bit
- Flatheat screw driver, Philips screw driver
- Socket set (8mm or 10mm required)
- Pliers
- JB KwikWeld
- Clamps
Optional Accessories:
- Butyl rubber sealant (recommended)
Step 1: Opening headlight
1) Pre-heat oven to 250 degrees F
2) Place headlight into oven making sure the headlight itself is not touching any walls or heating coils.
3) Wait 5-7 minutes (depends on your oven size)
4) Take headlight out from oven, while still hot to the touch, use flat-head screwdriver and begin prying apart from corner, releasing tabs along the headlight as you pull apart
5) Place headlight lens in a safe place
Now you should have this...
Step 2: Remove reflectors
The inner reflectors need to be removed from the housing to perform the necessary modifications for this retrofit.
1) Locate the two rear adjustment screws on the rear on the housing
2) Use your socket and turn counter-clockwise, alternating between both adjustment points
a) 10mm socket ›› 02-04 aftermarket headlights
b) 8mm socket ›› 02-04 OEM headlights
3) Unscrew all the way out until reflector is loose and can be removed
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Step 3: Prepping Mini H1 projectors
The projectors need to be disassembled before retrofitting. The Mini H1 projector is comprised of only several parts.
Projector assembly: the projector itself, does not need to be taken apart unless to wipe lens
Bixenon wires: wire/tap to factory high beam harness, activates bixenon solenoid
Silicone washer: sandwiched between the rear of the projector and the reflector bowl
Adapter plate: located on the outside of the reflector, centers the projector
Lock ring: tightens the Mini H1 to the reflector, can be lock-tighted or JB Welded for a permanent alignment
Bulb holder: necessary for the bulb and clip assembly, holds a H1 HID bulb in place
Screws and bulb clip: hardware to hold H1 HID bulb
1) Remove all hardware attached to the projector until only the projector assembly remains.
2) Place one silicone grommet over the rear flange of the projector to prepare for test fitting.
Step 4: Modifying reflectors
We need to use a Dremel now to make the necessary modifications to the reflector bowls so they can accept the Mini H1 projectors so that we can continue test fitting.
1) Remove the metal bulb cover from the reflector by prying the two tabs on the rear side, also remove the screw holding in the bulb clip.
2) Using your Dremel and a re-inforced cutoff wheel, cut the rear of the reflector until it is as flat as possible.
Make sure you DO NOT shave down too much as that will comprimise the strength of the reflector where the projector will mount, shave down just just enough so that everything is flush.
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3) Using your Dremel and a grinding stone bit, bore out the center bulb hole slowly until the Mini H1 projector will slide in.
4) Test fit the Mini H1 projector WITH the silicone grommet (Step 3.2). If the projector clears your bored hole and sits straight forward, continue on to Step 5.
If the projector seems to be pointing too far outward or too far inward as you test fit, you need to make a modification that wil help the projector sit in the correct position.
5) Using your grinding stone bit, grind the inside of the reflector to create some tilt in the mounting point to correct for the outward (or inward) angle.
Step 5: Attaching shrouds
Once you are satisfied with the fitment, we need to test fit your shroud and attach them.
1) Prep the shroud by installing the shroud-centric ring included with your shrouds.
Take one ring and press it into the backside of the shroud until it clips in. Install the rings on both shrouds.
Use some JB KwikWeld and epoxy the centric ring to the shroud by dapping some epoxy on the sides of the shroud.
2) Apply JB KwikWeld to the front lens holder of the projector. Slide the shroud over the lens holder.
Let epoxy cure to ensure a strong hold on the shrouds.
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3) Repeat for other side headlight.
Step 6: Re-sealing headlight
Re-applying extra butyl rubber glue is highly recommended if you want to avoid moisture and condensation problems after you complete the rerofit.
If you did not purchase re-sealing glue, skip 1), other continue.
1) Apply the re-sealing butyl rubber glue by slightly stretching while pressing the strand into the sealant channel of the headlight housing
2) Repeat for other side headlight.
3) Re-install the reflectors (now with Mini H1 projectors mounted and shrouds mounted) into the housings by tightening the two adjustment screws
Make sure to press the reflector into the ball & socket joint on the bottom if it does not do so on its own.
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4) Pre-heat oven to 250 degrees F and place the housing inside for 5-7 minutes (varies).
5) Remove the housing from the oven and immediately place the lens over the sealant channel and press firmly.
Use clamps and vice-grips if ncessary to make sure everything is as tight as possible. Make sure all housing tabs latch over once again.
You may have to repeat this process twice to heat the housing up enough on all sides for the tightest seal possible.
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5) Repeat for other side headlight.
6) Let newly retrofitted headlights cool before attempting to install onto vehicle and proceed with final step of aiming!
Finished product!
Step 7: Setting rotation and properly aiming your newly retrofitted headlights
ROTATION
1) Install headlights on vehicle, install bulbs, hook up ballasts, etc. Plug in bixenon solenoid wires into the factory high beam harness, or tap them into the harness if you wish to retain stock high beams in addition to the
bixenons.
2) Park vehicle on level ground and shine headlights against wall, observe rotation of the projector beam. It should be as close to absolute horizontal (0 degrees) as possible.
If rotation needs adjustment, remove headlight and loosen lock-ring very slightly on rear of Mini H1 projector just to give some play.
Rotate the projector slightly. Re-install light and light up and re-observe rotation until satisfied.
Take headlight off for final lock nut tightening to ensure no rotation occurs while tightening.
JB Weld or Loc-tite may be applied to the threads to prevent loosening of the lock-ring.
3) Repeat for other side headlight.
AIMING
1) Park vehicle on level ground approximately 25 ft away from a flat (preferably white) wall.
2) Measure height from ground level to center of projector lens, record measurement.
3) Observe height of headlight beam.
4) Raise or lower beam until it is 2-4" less than measured value in (2).
Aiming be done with headlights installed, use a long Philips-head screwdriver and insert from the top -> down.
5) When finished, you should have output similar to this...
Any specific questions not covered in this guide, please email <[email protected]>.
Good luck with your retrofit!
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