TracKick Projector Headlights

I have never been impressed with the headlights on our TracKicks.  Even new they were not very good.  Age has effected the reflector material inside, so they just do not do the job as they should.

A while back I ordered a pair of Nilight® 2.5" Mini HID Bixenon Projector Headlight modules to see if there was something that could be done.

One of my Trackers came to me with very poor headlights.  Rather than toss them, I figured on using these for experimenting.

You can see the black berry vines/leaves INSIDE these lights. I had already replaced them with some from my parts rig. (Even the "new" ones had a rock chip hole in one of them.)  These were in my scrap pile.

I tossed them in the oven at 180 degrees F.  After a while (longer is better) the glue/sealant is so soft the cover will come off with very little prying.  (Both were already broken and the first one shattered when prying after only 30 min in the oven.)

 The light guide/bulb shield needs removed.

Then, after cleaning, the projector can be installed.

They say the module is water proof.... but I can not see how it could be.  I need to figure out some kind of cover for the light. It isn't quite as easy as it would seem.

The projector is longer than the housing, but the stock glass cover/lens looks like it would cover them. The problem is, the stock lens has the lines that bend and distort the light... Yes, the stock bulb needs them to put the light where it is needed, but they are not needed for the projectors.  If fact it would likely scatter the light and cause glare to on-coming traffic.

I need to find something clear that would come close to the stock lens in height.  If plastic, I might even need more distance from the projector due to heat.

I may or not worry about duplicating the stock sealing surface.

Leaving the cover to think about, I wanted to see the pattern the projectors produce.  They say that these will work with "H1" bulbs or an HID H1 kit.

As this is just testing, I picked up a single H1 bulb. --> it did not fit the housing.

As I was tired at the time, I put it all on the shelf and will work on it later.

There is lots of room around the projector for angel/devil eye, LED daytime running lights or other additions.  There is even a reflector section (near the blinker end) that is un-used on North American Market TracKicks but are used in other markets. 

Comments, suggestions or ideas?

I'll get back to this... someday. ;-)

10/26/2016 -- update ----

I found my jewelers file set and filled out the projectors so the "rated" H1 bulb would fit.   When I went to power the bulb, I noticed there is not any ground connection on the projectors.   (An H1 bulb is very simple with only a single spade connection on the bulb itself.)   Even though they claim these are H1 projectors, I suspect they are pretty much meant to have "H1 HID" upgrades installed.

After rigging a ground I got it lit up.  I found that I had it installed upside down.   (High/Low beam "flapper" device actually goes on the bottom.)  When I got it straight,  and just testing in a darkened kitchen with a regular H1 bulb, it seemed like it had a "pretty good pattern" with a good cut off.

I also picked up some LED modules the might make good DRL's inside the housings.

When I have more time, I will take some pictures while I figure out some kind of clear cover to replace the stock lenses.