Fixing my lame "plug-n-play" headlights.

[Maven]

So I got some streetracingazian retrofits about a week ago or so, went to install them and found the harness all hacked and corroded to the point of it being worthless.




So the first order of business was just to replace the control box and harness, installed new harness and box to car, key to long life for these connections is a liberal coating of a quality dielectric grease, keeps moisture out and reduces the chances of issues caused by vibration.


After the install I found that the shutters for the highbeams didnt work. Well a little diagnosis found it was the ♠♠♠♠ty Chinese control box that was failed and not working the shutters. So I'll be completely replacing it with ballast control and shutter control harnesses of my own design and construction.

Instead of the shutters and ballasts all getting their control signals from just one headlamp socket connector like all the ebay/hid store harnesses do, I decided it would be better to to have the ballasts get their signal from one side and the shutters get their signal from the other side. Since the ballasts still work I just made up a shutter harness today (while at work )
First tinned the wires for between the shutters and the first shutter connector together:

Wiring used is 18ga thin-wall cross linked polyethylene(TXL), same as factory wiring, and far better than you get in any aftermarket harness, all connections are soldered and then sealed with adhesive lined polyolefin heat shrink.

After al the connections were made I wrapped the whole thing up in some nice abrasion resistant polyester tape. OEM+ y0!!!

The ballast control relay harness will be next, same attention to build quality, and OEM or better components. Ill be using the same TXL wire, dual weather proof fused power circuits and relays, one for each ballast. Cheapo harnesses use one power feed and relay to power both ballasts, have fuses that are open to the elements, and terminal not intended to survive in the underhood element. My connection at the headlight will be weather sealed(unlike the others) and the harness will be a direct quick connect to the underhood fuse block. I havent decided whether Ill secure the relays to the underside of fuse box lid or hide them somewhere else.

[Omiotek]

Hell yes do work

[Jn2]

A lot of work....

[RooTBeeR]

A lot of GOOD work...

[Mr.N00bLaR]

Wow, I don't remember the FS thread describing how F'd up the lights were, what an ass. Hope ya gave bad feedback...

[Maven]

Wow, I don't remember the FS thread describing how F'd up the lights were, what an ass. Hope ya gave bad feedback...

never even thought about leaving feedback.

[NASKRON]

Looks good maven, you are the mang

[Omiotek]

blows my mind lol...but you know what the guy gives cobalt owners what they want lol...cheap product that cheap asses can afford but for the few that are willing to pay they still dont get the good stuff..


this has to do in the collision world but the priciple can apply anywhere....i call it the 6 p's. PISS POOR PREP, PISS POOR PRODUCT and its the same vise versa.

[gcsd3742]

He gave me a price of $695.00 to make me some new headlights for the HHR I was like for $695.00 I will make them myself....He musta bumped his head on something.....Sorry you have to go through all the headache of fixing what you thought was the right thing the 1st time.....you shoulda seen the headlights i ordered the 1st time from a kid on HHR Forum. the kid hacked the whole headlight housing in 1/2 cutting off the mounting tabs as well. Then when I told him i wanted my $$$$$ back he cried about it all over the forum and told Paypal he said he told me he cut them and tried to melt plastic with a soldering iron to glue them back together. Paypal favored in my behalf and gave me my $$$$$ back....




Mounting tabs in a plastic bag. Really?

So I feel your pain .....Good luck, Nice job on the fix there.....

[RooTBeeR]

He gave me a price of $695.00 to make me some new headlights for the HHR I was like for $695.00 I will make them myself....He musta bumped his head on something.....Sorry you have to go through all the headache of fixing what you thought was the right thing the 1st time.....you shoulda seen the headlights i ordered the 1st time from a kid on HHR Forum. the kid hacked the whole headlight housing in 1/2 cutting off the mounting tabs as well. Then when I told him i wanted my $$$$$ back he cried about it all over the forum and told Paypal he said he told me he cut them and tried to melt plastic with a soldering iron to glue them back together. Paypal favored in my behalf and gave me my $$$$$ back....
Mounting tabs in a plastic bag. Really?
So I feel your pain .....Good luck, Nice job on the fix there.....

holy hell batman!

[Omiotek]

thats ♠♠♠♠ed! i dont think 695 is horrible for retros with the right parts because the parts itself can add up really realy quickly with GOOD parts. i priced all my stuff and its close to 450 bucks in parts alone now add the labor if someone wanted to have them done.

[qwikredline]

^^^^ this.

[Omiotek]

yep....this is why the custom fab, body, collision industry IS GOING TO ♠♠♠♠! insurance companies suck and people think 10000 in labor should be 1000 dollars lol.

[Maven]

6P as I know it: Proper Planing Prevents Piss Poor Performance......I made Dubbie a shutter harness :

[Omiotek]

theres the 6ps in every aspect of the industry. i know that one too.

[slvrred-]

^^^^^^ troof!

[gcsd3742]

so show us the finished product...

[Maven]

I didnt do the relay harness yet. Probably wont until I do my retrofits. see other thread

[gcsd3742]

In favor of seeing the finished product and the how to thread......I got extra sets of the HHR headlights but not the time or desire to do them just yet....want to see a good thread on how to do them the right way the 1st time. and what projectors to use.