The header was dusted/painted today, pre-fit, and the proper harness plugs were soldered in today. I'll be calling the Retrofit Source tomorrow with a few questions, if all is good, I'll get these ordered. Then it's on to baking some headlights...!!!

 

All the pieces seem to be here now. Conversion LED's arrived today, and the pass reflector housing had to be exchanged as there was a nice smudge-gerprint on the interior chrome reflector.
Usually my dealer lets me keep the defect parts, as ford seldom wants the minor stuff back. I was hoping to have a spare to practice on in the oven, but he said this one has to go back.
So no later than this weekend, we'll see what we can screw up.

 

Not going well. I opened up the drivers housing last night, only to realize that the threaded part of the projector diameter is too large to fit through the light bulb hole. I thought since I have already sacrificed the housing, I'd just drill out the rear to increase the diameter after a bunch of depth measurements. Once that was done the projector rear fit through, but with the bezel attached to the front of the projector unit, it ends up being jammed, and compressed in the reflector opening, likewise the reflector gets bowed out.
Apparently these projectors and bezels are not for these reflector housings. Since this is the only LED projector option they give for the 05-07 headlight housings, I'll be calling them on Monday. Looks like they will have to be returned.

 

I had a very similar problem with mine. The projector is fine, but the problem is with the round shaped shroud that was hitting the trim. See below picture. Next time around, I'll be ordering a couple of additional sets of 'square' shaped shrouds to avoid hitting that trim.

 

Did you ever complete this?

 

 

I did actually. Haven't driven at night to aim them, but they appear to be a massive improvement.


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