Email me at jdinh2@yahoo.com for pricing and information for the following
services:
• HID
projector and yellow
capsule retro fitted into head lights and
fog lights.
• Molded Fiberglass Bezel and Shroud for HID Projector.
• Instrument
gauges, window switches and A/C console modified to use LEDs.
• CPS-2
and CPS-3
board battery replacement.
• Dreamcast to JAMMA Converter.
Disclaimer:
All of the information provided here is supplied at face value with no warranty whatsoever and is to be used at your own risk. The author cannot be held responsible for any damages of any type coming from the use of the information provided. In other words, if you break anything or hurt someone else, yourself or something while trying to perform this modification, only you are responsible. The information provided here is for private use only and may not be modified, distributed or published without the author’s written permission.
Yellow
Fog Light Conversion
Version 1.0
Author: John Dinh (a.k.a. Meanbean)
Created On:
Introduction:
Have you every driven past a Lexus vehicle at night and wished for the same yellow fog lights on your vehicle? Have you purchased yellow fog light bulbs thinking that it will give you the same yellow color only to find out it doesn’t come close? My guide will help you to convert the factory fog light housing from a 97-99 Nissan Maxima so that it can output the same yellow color light just like the Lexus vehicles. While this guide is intended for use on a 97-99 Nissan Maxima, you may be able to apply the steps outlined to other make and model vehicles to produce similar results.
Tools and Supplies Needed:
1. Rotary Tool
2. Reinforced cutting wheel
3. 1/8” Drill bit
4. Flat and Phillips head screwdrivers
5. Wire cutter
6. Needle nose pliers
7. 10mm and 8mm socket and wrench
8. Painter’s masking tape
9. Aluminum tape
10. Goo Gone
11. JB Weld or your choice of epoxy adhesive.
12. Permanent or Dry-Erase marker
Parts:
Two Lexus yellow capsules
Note: If you are using a halogen H3 bulb (see Illustration 0.1) then the yellow capsule size used is H3. If you are using a HID H3 bulb (see Illustration 0.0) then the yellow capsule size used is 9006. This project used yellow capsule size 9006 along with the rebased HID H3 bulb.
0.0 Picture of HID
bulbs. One has been rebased to size H3
and the other is the standard OEM size D2S.
0.1 Picture of various bulbs showing size differences.
Installation Instructions
1.0 
Picture of the plastic retaining screw, marked by the yellow arrow, securing the fog light finisher.
2.0 
Use a Philips screwdriver to remove the plastic screw from the fog light finisher.
3.0 
Pull the plastic screw out to remove the fog light finisher.
4.0 
Picture of the two 10mm bolts, marked by the yellow arrows, securing the fog light to the mounting bracket.
5.0 
Use a 10mm socket and wrench to remove the bolts from the fog light bracket. Unscrew the fog light cap and disconnect the power and ground wires and remove the fog light housing. Place the fog light off to the side and repeat steps 1-5 on the other side to remove the other fog light housing.
Note: Steps 6-9 should be completed by those who are unable to remove the fog light lens from the housing through the oven heating process. If you are successful with this process, then skip steps 6-9 and proceed to step 10. Here is a brief description of the oven heating process.
A) Preheat oven to 275˚ and move oven rack to top spot or furthest away from the heat. This is done to lessen the chance of melting the housing.
B) Place the fog light on a cookie sheet and place in the oven for ~7 minutes.
C) Remove the fog light from the oven. Remember to use gloves or you will burn yourself.
D) While working your way around the lens, use a razor blade and a flat head screwdriver to slowly pry the lens from the fog light housing.
E) If the lens is not able to be separated from the housing then place the fog light back into the oven in 1 minute intervals and repeat steps C-E as needed. Do not leave the fog light in the oven for more than the 1 minute interval after the initial 7 minute heating process or the fog light housing may begin to melt.
A heat gun may be substituted for the oven heating process if desired. If a heat gun is used, remember to never leave it pointed in the same spot for more than a few seconds or the fog light housing may begin to melt.
While some have been successful in using the oven heating process to remove the fog light lens from the housing, I was not able to do so even with the use of a heat gun. Because of this, I used steps 6-9 to separate the lens from the housing.
6.0 
Use the marker and trace a line along the edge of the fog light housing marking where the lens ends. (See Illustrations 6.0 - 6.4)
6.1 
6.2 
6.3 
6.4 
7.0 
Attach the reinforced cutting wheel to the rotary tool. Use the rotary tool to cut into the housing while following the marked line. (See Illustrations 7.0 – 7.1)
7.1 
Be careful not to cut into the housing too deep at this spot since the reflector housing is closest to the plastic housing here. Not doing so may result in damaging your reflector housing.
8.0 
Use a flat head screwdriver to pry the housing apart, separating it from the lens. (See Illustrations 8.0 – 8.1)
8.1 
Picture of lens just separated from the housing.
9.0 
Remove the excess plastic shavings from the housing.
10.0 
Use an 8mm socket and wrench to disconnect the aiming screw from the reflector housing. This will cause the reflector housing to unsnap one of the retaining bolts from the back of the housing.
11.0 
Use a flat head screw driver to pry the remaining retaining bolt from the fog light housing, separating the reflector housing completely from the fog light housing. (See Illustrations 11.0 - 11.1)
11.1 
Picture of fog light fully disassembled.
12.0 
Use wire cutters to separate the bulb shield from the reflector housing at the points marked by the yellow arrows. (See Illustrations 12.0 - 12.2)
12.1 
Picture of the reflector housing with the bulb shield removed.
12.2 
Picture of the cut bulb shield.
13.0 
Trim off the excess length, circled in yellow, from the bulb shield.
14.0 
In its current form, the shield will not stay connected to the yellow capsule so it must be modified. If applicable, remove the shield from the yellow capsule before proceeding. Use the needle nose pliers and begin to bend and crush the outer edges of the shield, marked in yellow, on both sides of the shield. This will allow the shield to fit over the yellow capsule without falling off. Be careful not to make the shield fitment too tight or you may crush the fragile yellow capsule when you attempt to place the shield on top of the yellow capsule. (See Illustrations 14.0 - 14.1)
14.1 
Picture of the modified shield placed on top of yellow capsule.
15.0 
Remove the shield from the yellow capsule. Place the yellow capsule into the reflector housing and over the bulb opening. Try to center the capsule as best as possible over the opening. Use the marker to mark the points, marked by the yellow arrows, where the capsule bracket makes contact with the reflector housing. (See Illustrations 15.0 – 15.1)
15.1 
16.0 
Mask off the surrounding area of the reflector housing with painter’s masking tape in order to prevent damage from drilling. This type of tape is used to prevent damage to the reflective paint upon its removal.
17.0 
Attach the 1/8” drill bit to the rotary tool. Use the rotary tool and drill through the points previously marked. Remove the masking tape from the reflector housing. Use Goo Gone to clean the reflector housing. Do not use alcohol or window cleaner as these solvents will damage the reflector paint.
18.0 
Attach the type of H3 bulb to be used to the back of the reflector housing. Place the yellow capsule bracket through the drilled holes. Center the yellow capsule around the bulb so that the bulb cannot make contact with the yellow capsule. The bulb should have a clear area around it as shown by the red arrows.
19.0 
Use the needle nose pliers and bend the yellow capsule bracket points, marked by the yellow arrows, so that the yellow capsule can no longer wiggle inside the reflector housing while checking to make sure the bulb is still not making contact with the yellow capsule. (See Illustrations 19.0 – 19.3)
19.1 
19.2 
Picture of the yellow capsule now firmly attached to the reflector housing.
19.3 
Picture of the yellow capsule now firmly attached to the reflector housing.
20.0 
Attach the shield back on to the yellow capsule and remove the H3 bulb from the back.
21.0 
Mix the JB Weld or epoxy and apply it to the three mounting points marked by the yellow arrows. Be sure to allow adequate drying time prior to proceeding with the next step.
22.0 
Clean the plastic housing and lens with soap and water and dry them thoroughly. Reattach the reflector housing back on to the fog light housing by turning the aiming screw with an 8mm socket and wrench. Once the aiming screw will no longer turn, press down on reflector housing points, marked in red, to the allow the retaining bolts to snap back into the fog light housing. Now, mix the JB Weld or epoxy and apply it to the surrounding areas marked in yellow.
23.0 
Attach the lens back to the fog light housing and use strips of the aluminum tape to keep the 2 pieces connected while the JB Weld dries. (See Illustrations 23.0 – 23.1)
23.1 
Fill in any gaps, marked by the yellow arrows, with more JB Weld or epoxy. Since the JB Weld will not harden immediately, it may run down, marked by the red arrow, so be sure to clean up these areas. You may have to flip the fog light over and over to avoid the JB Weld from running down into the fog light housing while it dries. The JB Weld should start to solidify enough in 30 minutes so that constant attention will not be required. However, be sure to continue to check up on the fog light as you do not want to take the chance of the JB Weld running down on the inside of the fog light and ruining your hard work.
24.0 
Once the JB Weld has dried, remove the aluminum tape from the fog light. (See Illustrations 24.0 – 24.1)
24.1 
25.0 Congratulations, you have successfully modified your fog light with Lexus yellow capsules. Pat yourself on the back and when you are ready, repeat steps 6-24 on the other fog light. Once you are done, connect your fog lights back on to your car by following steps 1-5 in reverse. Turn on your fog lights and re-aim them as necessary. Now sit back and enjoy the light show.
Final Notes:
If you wish to make any comments about this tutorial or have any questions, email me at jdinh2@yahoo.com. You can also look for me, Meanbean, on these forums. Stay cool and have fun modding.
You can also look for me, Meanbean, on anyone of the forums I frequently visit. Stay cool and have fun modding.
http://www.neo-geo.com/forums/