***LS430 DIY Blacked out conversion w/ projector & leds**

GATO · 10-22-09, 12:15 PM

Here is a write up on my recent Do it yourself Lexus LS430 Headlight conversion.

So I took the plunge on doing this exhausting modification to my headlights.

Modifications include;
Double Projector, black housing, clear corners and 45 leds on each side.

I had previously placed my ES300 headlights in the oven, so, I had no fear in doing so on these.

The one thing I did ponder for some time was the electrical and to make sure those led’s lit up.
I’m quite the novice to these type of things, but once you get started, you just gotta figure out how to finish!

Comments good or bad are welcomed, Perhaps there was an easier way for those mcgyvers out there...........nevertheless, here ya go.

Tools and product needed:
Dremel (with cutters, sanders and drill)
Safety goggles
Black erasable marker
10mm socket
Mini zip ties
Screwdrivers
Chrome door trim
Razorblade
Krazyglue
Prismatic lighting panel (lowes or home depot 8 bucks)
Black electrical tape
Black spray paint (the one that bonds to plastic)
Clear Silicone (w caulk gun)
Chrome tape
_________________________________________
2 projectors
100 5mm leds (your choice in color)

Time: 13 hours for first headlight. 41/2 for second (you get fast after doing first one)

Start by removing headlight from car.
3 10mm bolts to get one side of bumper off and 3 10mm to get Headlight out.

These are the 5mm pre-wired led’s. they have built in resistors and are 12v application.

GATO · 10-22-09, 12:16 PM

This is the material used to insert leds. it has small pockets on backside, perfect for drilling your hole for led snug fit.

Now we make stencils out of this

Now dremel and cut out drawing

Make sure it lines up good

close up

with a erasable marker, you mark where how your gonna line up the leds

now smoothe out edges

the edges get pretty rough due to the melting plastic as you cut them
so, using the dremel sander to smoothe things out

here is the rough draft

GATO · 10-22-09, 12:16 PM

After all edges are fined down, I wrapped them in chrome plastic trim for a fuller look.

Time to cut holes. As Ideal as it would be to get a 5mm bit and just drill to perfection…..
The problem I found with that is that the plastc brakes as its too much to handle.
So, I got the smallest bit and drilled all holes first. Secondly, I edged them individually
So that the led fits snug.

secure all leds in place

and of course I couldn’t have done it without my little helper

while your in here chrome tape will cover the holes from taking the orange reflectors off

coming together. As you can see the wires do bunch up to quite a bit, so I made a window
to go towards the back

Here you can see all black are connected with extension to reach your power source and
Braded at the tip

after extending all wires and separating them positive and negative, you can drill hole
and zip tie the bunch like so

GATO · 10-22-09, 12:17 PM

Pre heat oven to 350 degrees and let it warm up for at least 15 min.
Turn oven off and wait 2 minutes.
Now stick headlight in oven using a foiled pan.
Leave it in for at least 10 minutes.
Take out and easily seperates.

now exposing what were going to paint

test fit projector

mask off for painting

I went the easy way on this and sprayed it with black spray (bond to plastic kind)
Originally wanted black chrome, but that’s 10 days to get back and didn’t have the down time that it takes.
Ok, so here is first coat

Remove the non projector highbeam housing

and make small adjustments where needed for projector install

now we are ready to mount black housing back together for sealing

back in the oven. Same as above. 10 to 12 minutes to let adhesive mend back to place

GATO · 10-22-09, 12:18 PM

The is the power source, positive and negative. This is the parking light wires so leds come on when parking lights are on.

positive and negative ready to connect

and here are the results

side view

and Night shot

carlos · 10-22-09, 12:27 PM

holy crap, thats some awesome work! not fond of the color but awesome nonetheless.

chrispy · 10-22-09, 12:44 PM

Amazing work GATO! Any close up shots?

SickSC3 · 10-22-09, 01:00 PM

awsome job on the diy any pictures and night??

JBLover · 10-22-09, 01:15 PM

That looks great! I would be too intimidated by all that stuff to even try to attempt that.

junjdm · 10-22-09, 03:28 PM

seen it in person!...absolutely sick!!!!!!!!!!

Tee · 10-22-09, 05:55 PM

Very nice! I really like the 2nd projectors added to the headlamp housing, I would like to see some shots wiith all the lights on. Great job Gato!

JP2SEA · 10-22-09, 06:08 PM

Great job!!! Is the light really that pink? That would attract popo

I did mine at 225 degree oven for 20min, the light came apart with ease. I've also used couple 2x4 soaked (water) under neath the light to prevent plastic from melting.

Your car is very clean!