DIY: Sonar Projector light dispersion fix

Big_Kokujin · 01-27-2009, 05:48 PM

Yes there is.

gravebox · 01-28-2009, 12:11 AM

yeah, i meant reseal, Dyslexia...

deezelium · 01-28-2009, 01:39 PM

Big K that couldnt be any more helpful thanks....I guess I will go search which is what I should have done in the first place.

Big_Kokujin · 01-28-2009, 02:10 PM

NP...its quicker too. and it wont yield smartass answers either

gravebox · 02-04-2009, 06:16 AM

ordered the new Toyota Denso OEM ballasts and will have updated pics of the light output.

i've gone and done the re-grinds like i mentioned earlier. i used this... huge thing... haha not sure what it was but it had a diameter of roughly 26 inches. after making the blocking plates flat the first time around, i took this... thing... and put the blocking plate under it at the two top corners and traced an arch from one side to the other and then used the table grinder to do the dirty deed and get the perfect arch going on the plate.

in about a week or two, i'll have update pictures showing the new projection zone. i lost my LED flash light

so i can't do teaser pics...

gravebox · 02-12-2009, 02:05 AM

small update

got ahold of another small flashlight. here's the rather dramatized version of the total mod. it wont be as dramatic of a arch as what's shown but should be close.

don't mind the glare, wont be there with the HID bulbs in there. that's just from the flashlight.

gravebox · 02-20-2009, 03:05 AM

UPDATE

the new dispersion is PERFECT!!!

only issue i'm having is a unexpected dramatic effect through the projector lens. with just 1mm shaved off the blocking plate, the once perfectly aligned headlight beam was now roughly 20 feet higher into the trees. even with aiming the lights to the maximum down, they are still much too high.

THE FIX

cook the sonars once again and pull apart the projector housing again. file down on the very edges where the plate mounts down about 1mm and reassemble. this should retain the wanted arch of light dispersion while countering the amount of added beam lift and will bring back the functionality of the aiming adjustments.

gravebox · 02-20-2009, 11:45 PM

UPDATE

blcoking plate fix did the trick. though i actually modified the projector housing more than anything really. the knobs that hold the blocking plate in place need to be filed down flat and then the step on the housing where the edge of blocking plate meets the step, you need to filed that step back about 1.5-2mm to move the blocking plate up in the right spot after that grinding of the arch. also, you'll need to cut the blocking plate where the bolt holes are laterally so that the plate can simply slide upwards into position.

i didn't take any pics of the mod fix but the text should be pretty clear hopefully. here is the ending result:

NO GLARE FTW!!!

after doing the aiming all nice and straight. it's the perfect balance between distance and cutoff. the cutoff point, so far that i've noticed, has been right at the top main body of the on coming traffic vehicle's doors. it's plain perfect.

powered by: Denso, Toyota OEM 2006+ generation digital ballasts.

pandorastoaster · 02-27-2009, 01:30 AM

I recently just ordered a set of these Sonars to replace my stock housings and I have yet to cook them because I'm not sure what sealant I should use when I put them back together, any suggestions?

gravebox · 02-27-2009, 04:34 AM

use black RTV, not Silicone

the reason why i say this is because RTV will easily allow you to re-cook your headlights again as long as you keep the original sealant that came with the headlights. the RTV wont stick to the sealant but it'll stick to the housing. it's strong enough to keep a good seal and but weak enough to rip apart when you need to. Silicone will be pretty tough...