: 05 Ody Projector Headlight retrofit
StupidPig 06-15-2010, 08:16 PM Well, since I brought a Civic as my daily ride a year ago (the gas price just too high for me to drive 100 miles everyday with the Odyssey), I didn't put a lot of time to play with my Ody (ohh.... it's no longer mine.... now it is my wife's car). Been spoiled by the HID projector retrofit on my Civic, I really can't think I can driver the Ody for the Legoland trip we planned on the Memorial Day holiday, so I rushed to finish the retro on the Ody before the trip.
The retrofit plan actually started about a year ago when I retro my Civic. I brought a pair of used headlight from ebay. I took the headlight apart at that time, by putting the whole light into an oven to soften the sealant and take the front lens out. Well, for smaller car like Civic, I really put the headlight into an oven, but since the Ody headlight is so big, I actually put it into a cardboard box and blow heat air into it with heat gun, to make it an oven.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/CardBox_Oven.JPG
Keep in mind don't blow the heat air directly onto the headlight, otherwise it will melt the plastic.
Depends on the box size, it take 15 - 20 mins, then the black sealant which holding the front lens and the headlight housing should be soften. With a flat head screwdriver, I pry the locking tabs around the headlight, and with some force, I took the front lens apart. The sealant is pretty sticky and I tried my best to not letting it stick onto the front lens, also I wear thick gloves since the headlight were pretty hot.
After I took the front lens out, I further disassembler all the parts within the headlight, I did that because the headlight I brought from ebay was full of dust inside, and I need to make it clean. For others want to follow with a good condition headlight, you don't need to remove everything. All you need is take the reflector out, so that you can remove the bulb cover.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Odyssey_Light_Apart.JPG
After that, the headlight basically sit in my garage until a week ago, which is the time I realized I must start working on it again for my trip.
The first thing I do when I started to work on it again is to black out the low beam reflector, which make the light look better based on my experience.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Blackout_Reflector.JPG
I used Duplicolor Engine Emamel Low Gloss Black (DE 1634), which so far I think it is the best for blackout the reflector.
StupidPig 06-15-2010, 08:17 PM This is the projector I selected, the "mini H1 projector". The benefit for this projector is the installation is super easy when compare with traditional retrofit. With traditional retrofit, you will need to cut a big hole on the reflector, then carefully mount and align the projector onto the reflector, which require a lot of patient and expertise to get it right. On the other hand, with this mini H1 projector, all you need is just put it through the low beam bulb hole and tighten the nut, no cutting/drilling is necessary.
Put it through the bulb hole...
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Installing_MiniH1.JPG
Tighten the nut....
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/TigthenTheNut.JPG
The red/black wires are the wire for the bi-xenon solenoid. Oh, did I mentioned the mini H1 is a bi-xenon projector? For peoples not familiar with the terms, bi-xenon means the projector can be used for both high and low beam.
Then I put the mini gatling gun shroud, which come with the mini H1 projector kit, onto the projector for a test fit.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/TestFitShroud.JPG
StupidPig 06-15-2010, 08:17 PM Since I have some CCFL angel eyes available, I decided to put those onto the headlight to used it as DRL (US 05 Ody doesn't come with DRL :().
CCFL on high beam area.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/HighBeam_AngelEye.JPG
CCFL on projector shroud for low beam area.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/LowBeam_AngelEye.JPG
And test fire for both angel eyes.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Dual_Angel_Eyes.JPG
StupidPig 06-15-2010, 08:19 PM Then I just put the reflector back to the headlight housing, and prepare the seal the front lens. To seal the front lens, in addition to
the original black sealant left on the headlight, I added the 3M Windo-Weld rubber sealer, which is commonly used by headlight retrofitter.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/3M_WindowWeld.JPG
I brought those from Kragen at about $15, which so far I used 1/4 for three retrofit already.
Make the rubber sealer thinner by carefully pull it longer, and then put it around the headlight (inside the groove where the original sealant located). Then reheat the original sealant and the Windo-Weld together with heatgun. I moved the heat gun slowly around the headlight for about 4 circles. Don't heat the same place for too long, or it will melt the plastic. When the sealant soften again, put the front headlight lens back to the housing, and use some clamps to secure it.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Seal_Front_Lens.JPG
The more clamps the better, and you will need to apply more heat around the headlight with the clamps on, to get the lens fully sit onto the housing. Make sure you also have all the tabs, which you pry open when you take the light apart, locked again.
Now the light is ready, time to do the wiring. As I mentioned, the mini H1 is a bi-xenon projector, so I need to connect it to both the 9006 low beam plug and 9005 high beam plug. I don't want to splice the OEM harness, so I get some 9005 and 9006 plugs and made a sub harness.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Odyssey_PnP_BiXenon_Harness.JPG
The 9005 part is a pass-through to the high beam bulb (so that when high beam, I have four lights) and tapped to powering the solenoid, and the 9006 part is going to connect to the HID ballasts. I have to say that I took a shortcut here, as normally I would always use a relay harness to power the HID. But since I'm in rush, and for the fact that I been ran 9006 PnP HID kit for a couple months about 2 years ago without using relay harness and no problem, I decide to take chance for this time and powering the projector directly from OEM harness.
I also added the male connector to the solenoid wires from the projector, so that it can be connected to the sub-harness.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/SolenoidConnector.JPG
StupidPig 06-15-2010, 08:19 PM Then I looking for a place to put the ballasts. There is a space under the headlight which looks like prefect for mounting the ballasts.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Ballasts_Mount_Location.JPG
I used scissor to cut some thin aluminum strips, then use bolts to mount the ballasts there.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Ballasts_Under_Light.JPG
Then I prepare the wiring for the CCFL angel eyes. I want it always on, so again I took a short cut to get the power from accessory socket inside the cabin, then use it to trigger a relay, which powering the CCFL inverters. To get the triggering wires from inside the cabin to the engine bay, it has to pass the firewall, which is easier than I thought.
Firewall opening on the engine side.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Firewall_EngineSide.JPG
Firewall opening on the cabin side (just above the accelerate pad).
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Firewall_CabinSide.JPG
StupidPig 06-15-2010, 08:20 PM Time to take the original light out and replace it with the retro.
First is take the bumper out.
There are 10 clips needed to be removed on top. The two marked in blue are longer.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Remove_Bumper_1.JPG
Then there are two bolts (one on each side) and 6 clips on the bottom. I can't take good picture of all the clips since I didn't jack up the van for the installation.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Remove_Bumper_2.JPG
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Remove_Bumper_3.JPG
StupidPig 06-15-2010, 08:21 PM Then another two clips on the top. (one on each side)
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Remove_Bumper_4.JPG
Then another two screws inside the fender. (again, one on each side)
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Remove_Bumper_5.JPG
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Remove_Bumper_6.JPG
StupidPig 06-15-2010, 08:22 PM After that, the bumper can be removed with force. Started from side...
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Remove_Bumper_7.JPG
Then bottom of the headlight. There are a couple tabs there, and you can use flat head screwdriver to help releasing it.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Remove_Bumper_8.JPG
With the bumper off, I also took the chance to put the gutter guard protector on, which I did once from outside 5 years ago and time to put a new one.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Gutter_Guard_Protector.JPG
After test fit I paint the gutter guard in metalic blue and use zip tie to secure it onto the bumper.
StupidPig 06-15-2010, 08:22 PM The next thing is take the headlight out.
One bolt and one clip on top.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Remove_Headlight_1.JPG
One bolt on the side
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Remove_Headlight_2.JPG
Then two bolt on the bottom.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Remove_Headlight_3.JPG
After that, it is pretty much hook up all the wires and put everything back in reverse order.
StupidPig 06-15-2010, 08:24 PM Then, here is how it looks like after put everything back.
At night (without light on)
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Front_View_Night.JPG
Day time.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Front_View_Day.JPG
Low Beam Output
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Output_Low.JPG
High Beam Output
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Output_High.JPG
StupidPig 06-15-2010, 08:25 PM A couple more pictures...
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/FrontAngleView_Day.JPG
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/FrontView_Day.JPG
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/Front_Driver_Day.JPG
The CCFL angel eye, as expected, is not very powerful for DRL usage, but still look good enough to me.
And here is where I tap the switched power for the CCFL relay trigger.
http://sites.google.com/site/stupidpigstore/mini-h1-on-3rd-gen-honda-odyssey/odyssey_minih1_pictures/AngelEyeFuseTap.JPG
rexxer 09-27-2010, 01:26 PM That's a great upgrade! I'm looking to do this on 2 Odyssey's. I'm sending you a PM.
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