Fabricating HIDs Into 1999-2004 Non-Halo Projector Headlamps

In this write-up, we go over the process of fabricating an HID kit into a Non-Halo Projector headlight for 1999-2004 Mustangs. The install is very similar to the Dual Halo Projector + HID write up we did earlier. It is important to note that the Non-Halo Projectors in this write up use an H3 bulb while the Dual Halo Projectors use an H1 bulb.

 

Tools Required

  • Phillips Screwdriver
  • Needle Nose Pliers
  • Dremel Tool with Circular Bit
  • Adhesive Sealant

Your first step in fabricating the projector housings is to remove the cover off the back of the headlamps. This is done by removing the five phillips head screws as shown circled below.

Once you’ve removed the five screws, the cover will pop right off and the picture below shows exactly what your left with. You’ll need to remove the black ground wire and stock halogen bulb (both circled in red) to prepare the housing for the new HID bulb and wiring.

Give the black wire a gentle tug and it will come loose. The bulb has to be removed from the housing by releasing the metal clip holding it in place. Depress the metal clip and the bulb will come free. Once you have the bulb free from the housing, you want to remove it from the blue power wire. This is done by taking your needle nose pliers and gently opening the female connector as shown below. Just a slight opening will allow you to remove the bulb.

Now, you are left with one blue power wire and one black ground wire as shown below. The HID bulb is now ready to be installed into the projector.

Insert the bulb in the projector and secure it by re-installing the metal clip. Please note,  the bulb fits into the housing correctly only one way. You should not have to force the bulb for it fit. This is what the headlamp looks like with the HID bulb installed.

At this point, we are almost done. Now you need to create an opening in the cover that you removed in the first step. This is required for the HID wires to pass through. Take the cover and measure 2″ from the top and 3/4″ from the right side exactly as shown in the picture below. Mark the intersection of these two locations. This is where you will need to create your opening. Please note, we are measuring from the top where the three screw tabs are located. If you accidentally take your measurements from the bottom side, then your opening will be in the wrong location.

We are using a 300 series dremel to make quick work of the opening. Notice the bit we are using.

You want to create an opening that is roughly the diameter of a quarter. It does not need to be pretty or perfectly circular. Your main concern is creating the opening in the right location. Use the dremel tool at a moderate speed and take your time.

Once you’ve got your hole cut and you’ve verified its large enough, pass the two wires coming off of the HID bulb and the blue power and black ground wire from the headlamp through the opening and re-attach the cover using the five phillips head screws you took off in the first step.

Use the adhesive sealant to seal up the opening in the cover. Be generous with the material and overlap the edges to create an air tight seal.

Your final step in the fabrication process is to connect the power and ground wires from the headlamp and HID harness. Take the red wire with male connector from the HID harness and plug it into the blue wire with female connector coming from the headlamp. Next, take the black wire with male connector coming from the HID harness and plug it into the black wire with female connector coming from the headlamp. The connections are shown below.

Pull the silicone sheathing over the connections to avoid contact between the power and ground wires as shown below.

Follow the same procedure outlined above for the other headlamp and your fabrication will be complete. The last step is to obviously install them in your Mustang! Here is the projector on our workbench with a 10K HID bulb installed.

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