Bi-LED Projector Retrofit
Old reflectors throw light everywhere except the road. We open the housing, fit a proper bi-LED projector with a clean cutoff, and set the aim so you actually see what's ahead without blinding anyone in the opposite lane. Most jobs are finished the same day in Newcastle.
What a proper projector retrofit actually changes
Halogen cups spray a soft, wide wash that fades fast on wet country roads. A bi-LED projector puts that same light into a tight beam with a sharp upper cutoff, so the bright part stays on the road and the glare stays away from oncoming drivers.
Sharp cutoff, clean beam
Every housing is checked on a beam setter so the cutoff sits at the legal height. You get a flat top edge instead of a smeared glow that reaches into the trees.
Sealed against moisture
Once the projector is in, we re-seal the lens with fresh butyl and run a quick fog test. No condensation inside the housing after the first cold morning.
Warrantable output
We fit modules that draw what the factory loom expects. No error codes on CAN-bus dashboards, no relay hacks, no flickering at idle.
Made for Australian roads, not a spec sheet
Most retrofit kits people buy online are built for European weather and city driving. Our installs are tuned for the conditions you actually meet out here, from long unlit stretches on the Hume to tight coastal bends and wet night roads where warm colour temperature cuts through the spray. We use projectors rated for a 40 degree ambient with proper heat sinks, so output stays stable on a hot afternoon sitting in traffic on the M1.
- Beam set on a calibrated wall to ADR vehicle alignment specs
- Copper-core heatsink and thermal path checked before sealing
- Loom adapter made to suit your specific chassis
- Two-year warranty on the module and the sealing work
We've opened a few housings
Retrofitting headlights isn't a bolt-on job. The housing has to be baked, split, re-keyed for a new projector base and sealed again, and we've done it across the cars that turn up in Newcastle every day, from Hilux and Ranger to older Commodore and Golf bodies. What we've learnt from 900-plus installs is mostly what not to do.
Pattern fitments, not guesswork
We keep the mounting templates for the common utes and SUVs so we're not carving out a housing from scratch on a Tuesday morning.
Thermal testing on the bench
Each install runs a 30-minute soak test with the housing on the bench, so heat creep shows up here instead of on your first long drive.
We drive them too
Fitters take the car out at dusk along the same back road before handover. If the cutoff sits wrong on a real road, we adjust it before you collect.
Straightforward pricing for a proper retrofit
Prices cover the projector module, the housing work and the beam set. If your housings have cracks or a failed ballast, we'll quote separately before we start.
Single housing
For damaged or one-off swaps where the other side is already sorted.
- One bi-LED 2.5-inch projector
- Housing split, re-seal and bench test
- Beam height set on our wall
- Loom adapter included
- 12-month parts warranty
Matched pair
What most people book. Both sides done the same day, aim pulled to spec together.
- Two bi-LED 2.5-inch projectors
- Both housings split and re-sealed
- Balanced left-right cutoff
- Wiring harness with CAN-bus filter
- 2-year warranty on parts and labour
Quad projector
For the larger utes and 4WDs with twin reflector housings and a big lens area.
- Four bi-LED 3-inch projectors
- Shroud trimming for a factory finish
- Two separate aim points per side
- Upgraded relay harness
- 2-year warranty plus free 6-month re-aim
How the retrofit runs from drop-off to keys back
Most matched-pair jobs are in by 8 am and rolling out by mid-afternoon. We'll text you when the bench test is done.
Pre-inspection
We photograph the existing housing, check for cracks and note any factory loom quirks before we touch anything.
Housing removal
Front bumper trims come off, the headlight units drop out, and the wiring is labelled so it goes back exactly where it came from.
Bake and split
The housing goes into the oven at a controlled temperature so the old seal releases without warping the lens or cracking the mounting tabs.
Projector fitting
The reflector cup comes out, the projector base is bolted into place, and the shroud is trimmed to match the housing shape.
Re-seal and bench test
Fresh butyl goes around the lens, the housing clamps up tight, then runs 30 minutes with the module lit on the bench.
Aim on the car
Back on the vehicle, we set the cutoff on our wall, take a dusk test drive, and adjust the left-right balance one last time.
Housings we've pulled apart this month
A quick look at the bench work behind the beam. Every photo is from a real Newcastle job.
Before you book the retrofit
Will this pass rego inspection in NSW?
Yes, provided the projectors are aimed to spec. We set the cutoff on our wall before you pick the car up, and we can attach a copy of the aim record to your paperwork.
Do I need to change the whole headlight housing?
Rarely. As long as the original housing isn't cracked through the lens or missing mounting tabs, we work with the existing unit and just swap the projector.
Can you keep my car's factory daytime running lights?
On most models yes. The DRL ring sits in its own reflector well, and our projector base is sized to leave that alone.
What happens if the housing fogs later on?
Bring it back within warranty. The most common cause is a cracked breather or a factory seal we couldn't save, and we re-seal it at no cost in the first two years.
Do you do mobile fitting in Newcastle?
No, the bench work, oven and aim wall are all at the workshop, so the car has to come to us. Drop-off and pickup are the same day for a set.
Send us the model, we'll quote the retrofit
Snap a photo of your headlight if you can. It saves a lot of back and forth about which housing we're opening.
- Reply within one Newcastle business day
- Quoted per housing, no surprises at pickup
- Free 15-minute assessment if you're local