yellow_cake

Hi folks, just thought I'd share my retrofit project on my 99 Maxima.

Components:
- Used Depo headlights.
- G37 sedan projector.
- '13 Cadillac SRX semi-clear lens.
- OEM G37 shrouds.
- Denso Slim ballasts.
- Osram CBI 66240 bulbs.
- Nichia Superflux white LEDs.
- exLEDs reflectors for superflux LEDs.
- Custom wiring harness + DRL & headlight controller.

Mounted using the JNC method, giving minor rotation and height adjustment on top of the factory reflector adjusters (vert + horiz).
For more info about the JNC mounting method: http://www.hidplanet.com/forums/show...model-pictures



OEM G37 sedan shrouds fitted.




After cutting the container, I used lots of JB weld to secure it into place.
Not shown, but there is also a bunch of epoxy around the inside for added strength. For that I used a self-mixing syringe type clear epoxy.




Here it is, fitment with the reflector mounted into the housing.
The empty containers were from workout supplements; different colours, but both were identical in size.




I used a sheet of balsa wood for the base, with some chrome vinyl for the front edge which will be visible.
The LED were secured into the reflectors with epoxy; the reflectors secured to the base & one-another with clear epoxy.




Home-made resistor array, clear-coated after everything was soldered to prevent the copper from oxidizing.








Epoxy'd the DRL base into place.



Cutout the top cover, also made from a sheet of balsa wood. Showing the bottom view where the chrome vinyl wraps around.
Prior to mounting, I spread epoxy all over to prevent the edges of the vinyl from lifting.



Epoxy'd the top cover. The reason I used chrome vinyl is so that the DRL assembly flows well with the rest of the headlight.



Close up of fitment.




The Denso slims had the short cords, this would be problematic for most retrofits...
I extended the wires while making the ballasts D2S/AMP hybrid. This will make headlight removal easier as well.



Soldered + adhesive lined shrink tubing. Notice how the solder joints offset one-another, good practice in case the joint or insulation fails (which it shouldn't, lol).

yellow_cake

Terminals crimped on.



Ooooohhh, aaaahhh... I'll be potting the ballasts as well.



Wires fished out through a rubber grommet.
Here's the wiring setup: The one loom has the DRL + solenoid wires, the other has the ballast cord.



Cap screwed on, sealing the back from dust/water.
The 3-pin connector wires: solenoid positive, ground, and DRL positive.




The rubber grommet at the bottom.




Headlight completed!





Here's the custom DRL controller + headlight controller.

The DRL controller has a dual brightness mode via an external PWM (ebay). Also, I've made it so engaging the e-brake will disable the DRL, just like the stock DRL. This will give me the ability to pull the handbrake up one click and have the DRLs off if I need to be stealthy, lol.

On the right is the low+high beam controller. basically it's a delay off circuit. Meaning, if the headlights are on and then turn them off, it will take about 2 seconds to shut off... I did this mainly for flashing while the headlights are off. This way it's not flashing the ballasts as they remain on in between flashes.


Ebay PWM at the bottom.



Potted the Denso ballasts.




Made a 9004 "connector" out of an old bulb. Removed the bulb and soldered wires onto the pins, then filled it with potting compound.



Eventually I plan on making an Arduino controlled DRL/headlight controller, it will have a fancy aluminum housing... For now, I've got the current setup wrapped in electrical tape... yea, it looks like a grease job, LOL.

yellow_cake

Installed.




DRLs on:




LEDs are dimmed when parking lights come on.

Low beams on:



I don't have output pics at the moment, but I'll get them in the next few days.

ChrisMan287

iTrader: (34)

Not a fan of the DRL strips (I feel like they just don't belong on these cars) but nice work

Great attention to detail.

CS_AR

^^ Nice job!

JoshG

very cool headlights, minus the strip lights.. it goes well on Mercedes, but these just keep it original and classic looking =d great job on them otherwise! i was curious how they look. but wasn't what i thought it would be.

Quickywd01

iTrader: (16)

Looked amazing till the ghey leds came on. You have to redo that part. Perhaps locate the strip to the top.

yellow_cake

Thanks for the critique guys. The LEDs are mounted rather permanently using epoxy,so removing them will likely butcher the headlights as well...

Meeting the legalities of a DRL was a challenge. The stock headlight runs the high beam at half power as the DRL. With an HID setup, my other option was to mount external DRL modules or run the HID all the time (not willing to do the latter).

cornholio

iTrader: (1)

can you add on to the led strips? something like one of the following?





i think it would look better if the strips filled the entire light towards the outside or even through the corners

cornholio

iTrader: (1)

idk just throwing some ideas

JoshG

maybe the led strip lights should be where the fog lights are at.

Finkle

What are the laws governing DRLs? I know Canadian law requires them, but is there laws governing brightness or location? I thought if I were to go with DRLs, I would use the front lens where the turn signal is. I moved my turn signals to the corner lights, so the middle bumper lights are pretty much for looks only. I can make them light up white or yellow. Or white during the day, then dim amber with parking/headlights. That would be cool

queenambeach

iTrader: (3)

Excellent job.....the LED pattern looks slightly off though.........

ChrisMan287

iTrader: (34)

Wow haven't seen you post in a long time.

yellow_cake

Thanks. I wish the LEDs could extend to the outer end of the headlight, but the shape of the headlight wouldn't allow it...

I am planning to convert the cornering lights to DRLs to make them look a bit more "complete."

JoshG

they're gonna have to be clear signals or otherwise they will look a bit off

queenambeach

iTrader: (3)

Yea, been buried under tons of work, but I still try to drop in and read from time to time.

queenambeach

iTrader: (3)

I know exactly what you mean, I'm working on a little DRL project myself and our headlights don't exactly lend themselves to favorable DRL spots. I think mines are gonna go where the front turn signals are.......I'm gonna use the 10W COB eagle eye LEDs. Those things are stupid bright.....

Crusher103

iTrader: (10)

One of the better retros i have seen in a while. I agree on what was said about the LED strip but definitely play around with them see what you can come up with. You have the skill to make just about anything you want out of them.

jholley

iTrader: (13)

Great retro and excellent details!

Just got a retro set delivered this week. I'll be inserting them in my black R34s sometime this spring.

nismomaxgtr18

iTrader: (5)

Love it! Glad to see there are people still out there doing new creative things to their 4th gens.

95naSTA

iTrader: (10)

Also not a fan of the DRL strip but the craftmanship on these is amazing.

tosheto

iTrader: (5)

What he said^

yellow_cake

Thanks for the input guys, I appreciate it.

I've got lots of lighting mods planned for the car! Hopefully I can get around to them and I'll definitely share once I do.

Jaehblue3

iTrader: (1)

I ended up putting my DRLs inside the turn signals because I wasn't agreeing with how they would look inside the headlight. Your install however looks very clean and thorough

yellow_cake

I actually have something like that planned. Just waiting for the parts to arrive before I can get to work on it.

VisciousMo

iTrader: (4)

nice retro!

Maximeltman

iTrader: (11)

Good job perfection I was thinking of doing one with angel eyes.

BPuff57

You, sir... are ridiculous. This is the coolest thing I've seen, today.

maxgtr2000

iTrader: (29)

Very nice work.

maxprivate

iTrader: (12)

nice craftsmanship.. as long as you're happy with your end result thats all that matters.