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Old 10-12-2018, 05:57 PM   #1
TheModfatherInc
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Default DIY 2010 2.5i Bi-LED Projector Retrofit Using OEM and Custom Parts

A quick synopsis of the project. 2017 Subaru Crosstrek Bi-Functional LED projectors removed and retrofitted into stock 2010 2.5i headlights. The project will use as many OEM parts as possible and the rest will be designed in house and 3D printed for the most part. I will also be repainting and polishing the ****ty headlights. This will not be a full instructional thread as these aren't the easiest lights to come by, nor am I a teacher, however I will document all the steps I take in detail in hopes the project can be replicated with similar parts... Here we go!

I just picked up this 2010 2.5i and of course it needed some work


Then my brother who works at a body shop brought home these 2017 (pretty sure) Subaru Crosstrek (Bi-LED Projector) headlights and said "Here do something with these"


And so we did...Heated them up and pulled the lenses off so we could tear them down and get the parts we needed.


We got them torn down and got the important part out. The OEM Subaru (ok Denso makes it but its OEM equipment) Bi-LED projector and electronics!



I couldn't find a wiring diagram for this online, so I had to trace the wires and then guess which ones powered the whole unit on. Didn't take too long to figure out.


And the cutoff shot i'm sure everyone wants to see (this is the passenger side projector)
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Last edited by TheModfatherInc; 10-17-2018 at 12:46 AM.
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Old 10-12-2018, 05:57 PM   #2
TheModfatherInc
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Time to pull the old lights out and apart! I forgot to take a pic of this before I tore it down but to get an idea of how awful they look... Don't worry, we'll buff those later!



Got the original projector out of the housing and surprisingly they're pretty close in size...


The High/Low Beam Reflector housing with the original projector removed


A little trimming and the new one doesnt fit terribly


Of course, the mounting points aren't even close so we fire up the laptop


Ok made some more changes and making progress


This is sitting a little low still, the top is hitting


This lip right here!


Lets shave that off with the dremel...



To be continued...

Last edited by TheModfatherInc; 10-12-2018 at 06:25 PM.
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Old 10-12-2018, 05:58 PM   #3
TheModfatherInc
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Ok that's better but now this hits


Lets cut it off


Print up the revised mount we started designing earlier...


Quick cleanup with a razor


Installed and fits GREAT


Integrated standoffs keep it spaced properly


Front view


Side view


Now I just need to whip up something to keep the bottom half from shaking all over the place.... Update soon!

Last edited by TheModfatherInc; 10-12-2018 at 06:35 PM.
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Old 10-12-2018, 06:25 PM   #4
TheModfatherInc
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Took some time to get the brackets just how i liked them. They have 4 points of contact with the projectors and 3 SECURE ones with the reflector housing. They're nice and sturdy. Looks pretty close to stock so far I think...






Also, painted the inner reflector bowls gunmetal, and blacked out the orange reflector. Step by step for this stuff by Overland04 https://forums.nasioc.com/forums/sho....php?t=2514614




Sanded the nasty yellow lenses and gave them a quick polish






Started on the wiring a little bit... I want to run more wires through that rubber grommet the headlight had, but how do i make the hole bigger?
Metal pen tube


Plus drill

Last edited by TheModfatherInc; 10-14-2018 at 11:57 PM.
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Old 10-12-2018, 06:25 PM   #5
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Just need to finish up the wiring and the solution i'm working on to mount the LED driver where the OEM HID ballast would mount on these housings. Also, need to get some led bulbs for the high beam housing to use as DRL since I cant run the projector high beams as DRL.

Last edited by TheModfatherInc; 10-17-2018 at 12:41 AM.
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Old 10-12-2018, 06:36 PM   #6
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Almost done! Got sidetracked with the finer details.
Re-wired the LED harness


Since my high beams are now integrated into the projector i don't need the high beam bulb, so I designed and 3D printed this adapter to use a 194 bulb base (off the Crosstrek light) in the HB3 socket


Installed

Last edited by TheModfatherInc; 10-17-2018 at 01:27 AM.
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Old 10-17-2018, 12:42 AM   #7
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The final part of this project to be completed are these LED Driver enclosures which will fit where the OEM HID ballasts would go



The final versions are currently printing on the 3D printer, so I expect to be able to get everything finished up tomorrow. All feedback is welcome
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Old 10-17-2018, 02:55 PM   #8
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Couple more hours of printing and this will be all set! First set of parts are off the printer and looking decent. I know the support interface could be better but its new filament i havent worked with a ton



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Old 10-17-2018, 04:34 PM   #9
What could go wrong
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Awesome idea! Will you be making the mount designs available? I'd love to print my own if I ever find a totalled crosstrek
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Old 10-17-2018, 08:31 PM   #10
TheModfatherInc
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Quote:
Originally Posted by What could go wrong View Post
Awesome idea! Will you be making the mount designs available? I'd love to print my own if I ever find a totalled crosstrek
Absolutely! Will share the STLs when its all said and done
Had a few print failures earlier with this new filament but things are looking good now!
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Old 10-17-2018, 11:54 PM   #11
TheModfatherInc
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Finished the wiring and printing the LED Driver boxes, need to grab the right size screws to attach the boxes to the lights, and reinstall tomorrow.




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Old 10-18-2018, 09:24 PM   #12
TheModfatherInc
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Just need to re-aim the lights. They aren't properly overlapped in the center since I couldn't find the right length extension to do the L/R adjustment. Great visibility.though. So far i'm happy.




Last edited by TheModfatherInc; 10-18-2018 at 09:29 PM.
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Old 10-19-2018, 08:41 AM   #13
scubaboo
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Very professionally done, bravo!
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Old 10-19-2018, 09:29 AM   #14
apkarian100
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Nice use of 3D modeling for your job.
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Old 10-19-2018, 10:55 AM   #15
TheModfatherInc
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As promised, the 3D files designed for this project can be found on my Thingiverse profile via the links below. I have also heard that these same projectors and LED Drivers can be found in the 2018 Totoya Camry headlights!

HB3 to 194 Bulb Adapter
Matsu****a Style LED Driver Enclosure
Retrofit Bracket/Mount
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