2010 GMC Sierra TRS Mini H1 Projectors Installed

grimmysnr · January 17, 2014

I know I have a 2500HD but the headlights are the same and this forum gets a bit more traffic so I wanted to show what these HID projectors looked like in a Sierra housing. First off the install went fairly well but there is some cutting and shaving required of the housing. I use this video:

to open up my headlights. I cut behind the lip with my dremel and just a standard cutting wheel. It seemed like the higher the speed of the dremel the easier the cut. Either way I probably went through 2 or 3 wheels per headlight. I did find that one has to be extremely careful prying on the lens to get it separated because if the plastic has not been cut all the way you can easily crack the lens. I ended up cracking a lens and had to order another light housing for $120 to replace it. This was my fault and I had a friend helping me who got his separated just fine. I think I just got too excited about how easy things were going. After the lens separates all that is necessary is some shaving of the area where the old bulb mounted. Just be forewarned that this mod is a one way ticket and if you want to go back to stock new housings are required. I found it necessary to not only open up the hole where the bulb was to get the projector installed but I had to remove some surface material in that area to get proper thread protrusion on the lock nut on the back side of the projector. I know it sounds scary but it really wasn't a big deal. Maybe the Silverado housings are better but for the Sierra a little bit more trimming was required than some of the writeups that I have seen. After the projector was installed I just used some Silicone II black caulk which has some adhesive properties to seal back up the light. Although it wasn't the prettiest sealing job I have ever done, you can't even tell the lens was ever cut on the final product. Any normal person would see the sealant and probably just dismiss it as "that's just how it is". I can tell its not right only because I was the one doing the job. I forgot to take pictures during the process so I only have pictures of the final product. I also tried to put some night shots together but it is pretty difficult due to camera lighting. Needless to say the beam pattern is excellent and you can visibly see the sharp cutoff. The cutoff is also visible when oncoming drivers pass and you can see that zero light ever goes above their side mirrors as they pass by. All of the light is directed out and down. I also hooked up the bi-xenon capability which flips down the shutter to let all 55w's of HID glory light up the road. With my high beams, aux lights, and HID's I can practically see into the future (yes I am exaggerating but you get the point). If you have questions please ask. Sorry for some dirt on the truck but here are some pics of before and after. All in all the whole mod including the curing of the sealant took a few hours on a Saturday night and I let them cure overnight to be installed Sunday morning. I would bet if you set aside a eight hour day you could be up in running by that evening.

Here is the cutoff in the garage with only one light installed.

white1500 · January 17, 2014

Awesome lights!

And never apologize about dirt on a truck. ;)

BoltRipper · January 19, 2014

What did it end up costing you for parts? I am very interested in doing this!

grimmysnr · January 19, 2014

The projectors were $120 and I picked up a couple of their 5k h1 bulbs for about $15-20. I went to Lowes and about $10 later I had cutting wheels for my dremel and the black caulk for sealing. I suppose I can say that the $120 for an extra headlight was a part of my costs but I don't think it should count simply because I caused the problem. If I had slowed down a little then that would have saved that money. I guess I have a good practice light now for something.

It all depends on what you already have in materials. I already had a 55w HID kit and the only reasons I needed to get the bulbs was because the projectors needed an H1 style vs the normal headlight. You would also need a dremel or some other method to cut like a dremel. DDM tuning has complete kits for about $60 and I have had their kits in both of my vehicles for 5-6 years with no problems. So that might save a little cash.

So the grand total for me was about $150 because I had most of what I needed (the hid kit). Since you wouldn't need a bulb from these guys I would think the final tab should come out to about $180-190 including the HID kit.

dsmmace · January 19, 2014

I love this. I wish someone would offer this as a service.

white1500 · January 20, 2014

There a lot of companies that offer this. Try lightwerkz.com or search for them.

grimmysnr · January 20, 2014

I had considered some of those retrofit services and some were upwards of $400 or more. I figured i would save the cash and if necessary I will buy spare parts if I mess up. Unfortunately I had to put the spare part backup plan into action but probably still saved a considerable amount of money doing it myself. If you do have the cash for those services though I would encourage it since you would probably get a far better looking product.