How to tsx projector retrofit
Sep 1, 2013, 09:01 AM
#1
How to tsx projector retrofit
Okay well folks I have always wanted to know how to retrofit my headlights I asked around but nooone wasn't really that much help. I checked around on hidplanet and they are helpful for what I had to do now lets get down to business.
I hope with the approval from everyone on here including the moderators would oblige to authorize this post for many others to learn as I went through to help bring this project to you to help make it easier for others to try this.
Now with stock projectors on the evolution 8 or 9 they unfortunately do not put out that much light output. This would definitely raise concern with issues with safety for someone not to see you. I don't understand how Mitsubishi to overlook this on such a good car.
Here are some of this tools and parts you will need to complete your task:
2x oem tsx headlight projectors from the retrofitsource.com $200 with clear lenses
1x 3Mribbon sealer from autozone $10 bucks works well you will need this to seal up your headlights
4x#6 washers The home depot
flat washers #10 part number 030699324811
#8 18-8 lock washers medium split part number 030699325917
4x 8/32 x 1.5 bolts they also come with the nuts at the ends too make sure to fit these up with crush lock washers to make sure the projectors wont come loose while you drive you know.
You will also need 1 power drill with titanium bits from Ryobi for the least resistance 3/16 in size. this will be used to modify the projector fitting it with 2 extra holes to line up the projector to cross fit it to oem specifications. You can find that in the tool section.
8x 2 inch spring clamps to hold the headlight together as you will need it to hold the headlights in place to prevent them from coming apart part number 573-682 as the 3m window ribbon sealer along with the oem sealant cools off sealing the headlights so that there is no condensation you don't need that.
okay now lets start by removing your from bumper lets start off by parking the car on even ground and pull the e-brake up. No need to jack the car unless your lowered you will need some hex keys and 8mm wratchet wrench under the fender to separate the bumper. It should look like this:
After unbolting the headlights they should have about 4 bolts holding the headlight to the chasis. Then you lift and pull then from there you take the headlights very gently and disconnect the bulbs from the housing its simple.
once your done taking out the bulbs and plugs they should look like this<br />
Once you are done it should look like this
Now keep in mind when you have your headlights in the oven you have to be careful that you don't burn them up. So as a precautionary safety measure you will need some extras for the bake session of your headlights. First you will need one small frying plate and you will need some cardboard....yes cardboard to make sure that you don't nuke your headlights. Now since the metal is hotter than the plastic it will melt it the cardboard works as a cushion for heat for the duration of the bake session.
The time to put your headlights in the oven should be 220 degrees or 130 fahrenheight for 15 minutes but you must preheat it for 5 minutes first for a total of 20 minutes. Warning you will need oven mits to make sure sure you don't burn your hands since the glass gets extra hot.<br />
Now when dealing with your headlights you want to carefully pry your headlights apart you will feel the headlights getting loose that's good. Now if you feel that the glue has cooled on the headlights after heating them up put them in the oven again for another 5 minutes.<br />
After opening up your headlights you want to carefully remove them with caution since the plastic shields in front which is the center section behind the glass before you get to the housing when you are prying them apart so be very careful with the screwdriver folks. Okay here are some pics after prying the headlight apart.
stock oem projectors opened
Stock oem projectors still in the housing
Removal of oem projector:
Okay first off let me explain more about the oem projectors are a problem to get off with the screws. So I ended up dremeling mine off with the dremel reinforced fiber wheel should cost 5 to 6 bucks from the homedepot. Dremel to screws off that are on the projector but be careful not to damage the brackets since you will need them to put on your oem tsx projectors with clear lenses.
Here is the bracket with the oem projector
this is the projector removed from the housing
Now with your tsx projector take the original oem brackets and line them up you will be using the top holes of the projector. Then you have to drill through the bracket lining up with the projector drilling through that making holes for it so that it looks stock like so:
Now with the oem projectors they don't quite line up with the shroud reflector in the picture seen here so I had to line up the projector giving it enough clearance to make room shown here. I had to shave very close to the bolt to make it work and it did seen here:
Now remember the projector when holstered up you have to have the bolt go through and its 1 lock washer to the back of that with a washer and to the end where the brackets hold it up you want 1 washer front and back with 1 lock washer front and back locking them in place with the nut.
Should look like this when its done
testing the beam out for precision put two washers at the bottom if you would like to color-mod your projector any more than two you wont get that crisp cut off
Its too bright to catch it on camera
Now when when putting out the butyl sealant on you can thin it out some since you still have sealant on there don't put down too much since it will overflow out the top when the headlights are clamped together using the 2 inch clamps I mentioned earlier remember to put these on after rebaking them back in the oven at 220 degrees for 7 minutes then put the clamps on: Set them in place like so
When your tsx projectors fog up don't panic just let it cool and it will clear up. Installation is reverse of removal. Enjoy! if you need me to do tis for you I offer my services just pm me
two more pics added
for some odd reason as sharp as it is the camera is not picking it up well enough. Perhaps I should do video of it too.
im going to get more by tonite.
Well sorry for the late reply here are some more pics again my phone is not the best.
my hids are 6000k's
I hope with the approval from everyone on here including the moderators would oblige to authorize this post for many others to learn as I went through to help bring this project to you to help make it easier for others to try this.
Now with stock projectors on the evolution 8 or 9 they unfortunately do not put out that much light output. This would definitely raise concern with issues with safety for someone not to see you. I don't understand how Mitsubishi to overlook this on such a good car.
Here are some of this tools and parts you will need to complete your task:
2x oem tsx headlight projectors from the retrofitsource.com $200 with clear lenses
1x 3Mribbon sealer from autozone $10 bucks works well you will need this to seal up your headlights
4x#6 washers The home depot
flat washers #10 part number 030699324811
#8 18-8 lock washers medium split part number 030699325917
4x 8/32 x 1.5 bolts they also come with the nuts at the ends too make sure to fit these up with crush lock washers to make sure the projectors wont come loose while you drive you know.
You will also need 1 power drill with titanium bits from Ryobi for the least resistance 3/16 in size. this will be used to modify the projector fitting it with 2 extra holes to line up the projector to cross fit it to oem specifications. You can find that in the tool section.
8x 2 inch spring clamps to hold the headlight together as you will need it to hold the headlights in place to prevent them from coming apart part number 573-682 as the 3m window ribbon sealer along with the oem sealant cools off sealing the headlights so that there is no condensation you don't need that.
okay now lets start by removing your from bumper lets start off by parking the car on even ground and pull the e-brake up. No need to jack the car unless your lowered you will need some hex keys and 8mm wratchet wrench under the fender to separate the bumper. It should look like this:
After unbolting the headlights they should have about 4 bolts holding the headlight to the chasis. Then you lift and pull then from there you take the headlights very gently and disconnect the bulbs from the housing its simple.
once your done taking out the bulbs and plugs they should look like this<br />
Once you are done it should look like this
Now keep in mind when you have your headlights in the oven you have to be careful that you don't burn them up. So as a precautionary safety measure you will need some extras for the bake session of your headlights. First you will need one small frying plate and you will need some cardboard....yes cardboard to make sure that you don't nuke your headlights. Now since the metal is hotter than the plastic it will melt it the cardboard works as a cushion for heat for the duration of the bake session.
The time to put your headlights in the oven should be 220 degrees or 130 fahrenheight for 15 minutes but you must preheat it for 5 minutes first for a total of 20 minutes. Warning you will need oven mits to make sure sure you don't burn your hands since the glass gets extra hot.<br />
Now when dealing with your headlights you want to carefully pry your headlights apart you will feel the headlights getting loose that's good. Now if you feel that the glue has cooled on the headlights after heating them up put them in the oven again for another 5 minutes.<br />
After opening up your headlights you want to carefully remove them with caution since the plastic shields in front which is the center section behind the glass before you get to the housing when you are prying them apart so be very careful with the screwdriver folks. Okay here are some pics after prying the headlight apart.
stock oem projectors opened
Stock oem projectors still in the housing
Removal of oem projector:
Okay first off let me explain more about the oem projectors are a problem to get off with the screws. So I ended up dremeling mine off with the dremel reinforced fiber wheel should cost 5 to 6 bucks from the homedepot. Dremel to screws off that are on the projector but be careful not to damage the brackets since you will need them to put on your oem tsx projectors with clear lenses.
Here is the bracket with the oem projector
this is the projector removed from the housing
Now with your tsx projector take the original oem brackets and line them up you will be using the top holes of the projector. Then you have to drill through the bracket lining up with the projector drilling through that making holes for it so that it looks stock like so:
Now with the oem projectors they don't quite line up with the shroud reflector in the picture seen here so I had to line up the projector giving it enough clearance to make room shown here. I had to shave very close to the bolt to make it work and it did seen here:
Now remember the projector when holstered up you have to have the bolt go through and its 1 lock washer to the back of that with a washer and to the end where the brackets hold it up you want 1 washer front and back with 1 lock washer front and back locking them in place with the nut.
Should look like this when its done
testing the beam out for precision put two washers at the bottom if you would like to color-mod your projector any more than two you wont get that crisp cut off
Its too bright to catch it on camera
Now when when putting out the butyl sealant on you can thin it out some since you still have sealant on there don't put down too much since it will overflow out the top when the headlights are clamped together using the 2 inch clamps I mentioned earlier remember to put these on after rebaking them back in the oven at 220 degrees for 7 minutes then put the clamps on: Set them in place like so
When your tsx projectors fog up don't panic just let it cool and it will clear up. Installation is reverse of removal. Enjoy! if you need me to do tis for you I offer my services just pm metwo more pics added
for some odd reason as sharp as it is the camera is not picking it up well enough. Perhaps I should do video of it too.
im going to get more by tonite.Well sorry for the late reply here are some more pics again my phone is not the best.
my hids are 6000k's
Last edited by impact blue; Sep 5, 2013 at 07:26 AM. Reason: had to clean up the thread
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Sep 8, 2013, 06:15 PM
#10
Nice job. 1 thing I would suggest to you or anyone else doing this - Use locktite red on the screws and nuts you used to assemble everything around the projector housing. I've been doing retrofits for about 5 years and that's one thing I learned the hard way 
Sep 23, 2013, 05:49 AM
#14
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oh my gawd! i've done retrofits to my prius and i've done a quad projector on my WRX. i really didnt want to do it to my Lancer, but thanks to you i have revisited retro fit source dot com and hid planet. thanks! haha! looks good with the exception of the pictures.