How to Retro Fit Projectors in a 300M Fog Light

[IS300M]

Ok, so after searching http://www.hidplanet.com/forums/ I decided that it was time to try retrofitting projectors into my fog lights. The only problem being is that our Fog Lights are so small not every projector is going to fit in without modifying the outside housing itself. So I ended up using Halogen Projectors from an Audi TT Fog light, they are made by Bosch and
Accept an H3 bulb.

Parts needed:
1. Bosch Mini H3 Projectors http://www.hidplanet.com/halogen.html
2. Six 2" Stainless Bolts with nuts and washers
3. Some kind of material for a shroud

Tools Needed:
1. Dremel
2. Cutting Disks for Dremel
3. Barrel Sander for Dremel
4. Screw Drivers
5. Socket Set
6. Drill
7. Drill Bits

http://www.cis.umassd.edu/~u_sgeary/300MPic/FogMod/Projector.JPG

Step 1: Disassemble the Stock Fog Light

http://www.cis.umassd.edu/~u_sgeary/300MPic/FogMod/Back.JPG

(the reflector pivots on 2 pivot points on the left and right side, pry those up with a narrow Screwdriver but do not pull on the reflector yet, if you do you will break the aiming adjuster) with it loose from the pivot points, turn the assembly around and begin unscrewing the aiming screw from the reflector, now it will be completely separated.

http://www.cis.umassd.edu/~u_sgeary/300MPic/FogMod/OEMFogParts.JPG

You can see the black plastic piece that accepts the aiming screw in the upper left corner of the reflector bowl, be very careful with this and pop it out so its not in the way do not break this. Then remove the screws that hold the bulb holder assembley to the reflector bowl.

Step 2

Cut the Reflector bowl to accept the projector

http://www.cis.umassd.edu/~u_sgeary/300MPic/FogMod/CutReflector.JPG
http://www.cis.umassd.edu/~u_sgeary/300MPic/FogMod/BackSide.JPG

You need to cut the square closer to the tallest part of the reflector cause that is where the projector fits the best

http://www.cis.umassd.edu/~u_sgeary/300MPic/FogMod/TestFit.JPG

Once you have the cutoff of the projector completely level with the bottom of the reflector bowl ****MAKE SURE THE CUT OFF IS LEVEL**** (you can see the cut off line in the glass), mark through the projector mounting holes on the reflector bowl so you know where to drill for the bolts to go through. Drill the holes for the bolts as straight as you can so the projector sits straight in the reflector bowl. Mount the projector with the bolts and attach the shroud (I used an Extra-Large Tea Strainer)

http://www.cis.umassd.edu/~u_sgeary/300MPic/FogMod/TempShroud.JPG

Once the projector is mounted and shroud is attached make sure no stray light can get through the sides (I used Aluminum Foil Heater Tape). You may need to grind some metal off the projector, if it sticks out side of the over all edge of the Fog Light to make sure the assembly is fully aim able. Now all that is left is to reassemble the Fog light and install it in the car.

http://www.cis.umassd.edu/~u_sgeary/300MPic/FogMod/Installed.JPG

I need to get some more output shots, but here is one:

http://www.cis.umassd.edu/~u_sgeary/300MPic/FogMod/ProJectOutput.JPG

Just the Foglights:
http://www.cis.umassd.edu/~u_sgeary/300MPic/FogMod/FogCutOff.JPG

Hid's and Foglights: (if you look closely you can see the Fog Cutoff under the HID Cutoff)
http://www.cis.umassd.edu/~u_sgeary/300MPic/FogMod/ComboCutOff.JPG

[Sneke_Eyez]

Great write-up Scott!

So, how much to get you to retrofit a set of projectors into a set of Intrepid fogs for me buddy??

[Hypnotiq]

Great Tut. Im gonna attempt this tonight after work. I got a set of HID projectors i just got for free last night from my buddy that works at lexus. There were from a Lexus RX that has the Pivot turn system. Hope it all works out.. ill keep ya'll posted.

[IS300M]

Great Tut. Im gonna attempt this tonight after work. I got a set of HID projectors i just got for free last night from my buddy that works at lexus. There were from a Lexus RX that has the Pivot turn system. Hope it all works out.. ill keep ya'll posted.

measure them first to make sure they will fit, its very very tight in the 300M foglight

[Hypnotiq]

They are 3" Projectors. Im gonna do some cutting and see what i can whip up. Any advise before i get started or anything i should use as far as sealing them?

[IS300M]

They are 3" Projectors. Im gonna do some cutting and see what i can whip up. Any advise before i get started or anything i should use as far as sealing them?

I did not have to seal mine because I used the factory seal the projectors I used fit inside completely. For types of sealant, I would use silicone, or some kind of butyl rubber.

[Avenger]

Anyone know if larger projectors will fit an Intrepid foglight housing? This is pretty cool, but I'd prefer larger projectors if I could make them fit!

[IS300M]

Anyone know if larger projectors will fit an Intrepid foglight housing? This is pretty cool, but I'd prefer larger projectors if I could make them fit!

You probably can, cause the height of the projector isnt as limited as it is in the 300M fog light assembly.

[freezingbelow]

Great write-up Scott!

So, how much to get you to retrofit a set of projectors into a set of Intrepid fogs for me buddy??

I was thinking the same thing...

[Linuxglobal]

Anyone know if larger projectors will fit an Intrepid foglight housing? This is pretty cool, but I'd prefer larger projectors if I could make them fit!

the bosch mini is prob up to par with other units the same size, bigger wont mean better so i would stick with the bosch or a 2005 + maxima fog unit.

CM

[300maximilien]

Those minis are disco...has anyone found suitable replacements?

[MurderM]

So Scott, when you planning to mass produce these?

[LUISA]

Any one wanna try to attempt this?,or should ask if there is anymore interest in this mod for our LH's? ;)

[gn300]

1st gen LHS fog lights are projectors are they not?

My thoughts on modifying fogs are still this.

Do the same thing as shown but add the housing that holds a h-4 headlight bulb.

This will give you the fog on low and a driving light on high!

Wiring will not be a plug and play but not terribly hard!

Waiting to see what replaces my LHS before i set out to do this!

Adding yellow bulbs would be nice as well!

[Meanmugga]

1st gen LHS fog lights are projectors are they not?

My thoughts on modifying fogs are still this.

Do the same thing as shown but add the housing that holds a h-4 headlight bulb.

This will give you the fog on low and a driving light on high!

Wiring will not be a plug and play but not terribly hard!

Waiting to see what replaces my LHS before i set out to do this!

Adding yellow bulbs would be nice as well!

I thought numerous times, about using 1st gen LSH projectors. Never got around to actually separating one from the headlight housing.

[Striker98]

Hey Scott, So those projectors fitted right into the housing without having to cut the back out so it is fully sealed?
What would you recommend for a shroud as I can't find tea strainers like yours. Thanks.

[Striker98]

Anyone else try this since scott? I just got my hand on some projectors and going to try and give it a shot.