Barcelona Red retrofit headlights /taillights

So I decided to start a thread on these headlights (actually it was suggested) I’m retrofitting with projectors and other goodies.
Starting with the Gen 3 stocks...

Then after the oven at 220F, 20 min, the permaseal becomes somewhat soft. Ive disassembled Tundra headlights before, and I can get it done with a couple flathead screwdrivers and only once in the oven. I start at the bottom of the light, and continue around the inside (blinker), over the top, and do the outside (side marker) last. Using one screwdriver to hold the area that’s already pried open, I use the other to continue around the headlight. Making sure to remove all the sealant from the groove so there’s no issues resealing.

This is everything disassembled, minus the housing and lenses, which are covered safely from dust. The chrome pieces get sanded with 320 and cleaned with wax/tar remover. The side marker lenses already have TRD vinyl stickers on them as a masking for tint spray.

I use 2 coats plastic safe primer then resand with 600. This also goes for the light buckets not pictured.

The sidemarkers getting tint spray. About 4 coats over the vinyl emblem, dried, then removing the vinyl.

Soooo, the paint company screwed up my order. Need to reorder...

Jumping ahead. The bezels have a basecoat on them now, and the buckets and dummy drls have a couple coats of black and then 2k clear.

Dry fitting the projector, before painting the shroud.


Aaaand the 3R3:Barcelona Red has arrived.


I’ll add to this thread as I build, as well as list the electrical components.

 

Sequential turn bars. These trim easily and I just drilled a hole in the left of this dummy drl space. Still figuring on how to keep it tightly installed.

 

Schweeeet!

 

Very nice work and write up. Bad ass lights!!

 

The new HID setup. This was the scariest part for me. I don’t have a lot of experience with HID, but the Morimoto harness made everything simple (relatively). It connects the battery and your stock headlight plug to the ballasts and has plug and play harnesses for the high beams.

 

Nice work so far Geno!! Following...

 

Damn you! Now I want to do mine!

 

Following this just because lol.

 

Looks good, ready to see the finished product. Are you leaving the old turn light signal locations blank?

 

Nice work, great ideas!

 

Cant wait to see these installed. Are these going on the blue tundra?

 

Thanks for the write up, this oughta help when I redo mine. The first retofit was done (not by me) with cheap ass drls that failed in the first year.

 

Thanks! Gonna put led ambers in for now. May put switchbacks.

 

Nope! These are being done for a friend. Mine are next with different ideas.

 

A little custom work. Painted black with a couple coats clear. Layed down a vinyl stencil, then painted over 3R3 paint code. After removing vinyl, it will get wet sanded and 2K cleared

 

Thanks! I wish I could post a video of them.

 

Mini projectors I grabbed off Amazon;
A little modification to the dust boot to keep things waterproof; and Morimoto H1 holders to keep the bulbs straight.

 

2K clear. Testing the electronics in a bit.

 

God

This looks really good

 

Looks bad ass she’s going to be super happy

 

They look great. Don't forget to stick some silica packs in there before you seal them back up

 

Just ordered. Thanks!

 

Before closing them up, I would recommend mounting on the truck to verify the cutoff is level. I had to modify the morimoto bulb holder adapter plate for the D2S projectors I am working on. Before modifying the little plate, the cutoffs formed a 'V' on the wall. I dremeled off a little material on the 3 tabs on one side to allow me to rotate the projector to be level

 

Those look amazing. Nice work so far.

 

Looking great!

 

Yep! I mounted them yesterday. They were both rotated to the left quite a bit. I did the same thing to the 3 prong adapter plate to rotate them back. But thanks for the tip!

 

Time for the tails! I used a dremel with a cutoff wheel to cut the taillights in half. Stayed about 1/4 inch away from the edge of the plastic.
Headlights are not sealed yet.

 

Youve got Big balls man lol
I know you have done it before but still that seems daunting to me. After you dremel them apart, how do you seal them up?

 

Lots and lots of chewing gum!

 

I use plastic 2 part epoxy. It works fantastic. Ive pulled apart my stocks and pulled apart my aftermarkets like 4 times! I had condensation once, but that was because I missed a spot. The newer way I’ve been sealing them is 4 spots with epoxy to hold it together, then black silicone to seal everything. No leaks in my aftermarkets so far 3 months.