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Old 08-27-2010, 10:41 PM   Thread Starter #1
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Default How to Install Halos

Courtesy of MaxPower

Installing Halos

Here's some Install information I threw together.
Tools/ Supplies needed
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1. Remove your grill

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2. Lower your front Bumper

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3. Remove Headlights

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Whether you bake your headlights or use a heat gun, the installation instructions after opening your headlights is the same. You can also follow the instructions posted below with detailed pics.

1.Open lights, (paint if needed)
2.Optional, use orange reflector as a template and cut out a clear sidemarker from flourescent drop ceiling cover, bought and a home depot.
3.Attach Halos to the inner headlight cover with epoxy.
-Drill into housing for a mounting point for each bottom portion of the halo.(4 holes per headlight)
-Epoxy glue the halos into those holes you drilled.
-Use small amount of Epoxy glue to hold the upper center part of the halo to the inner cover. (this makes it stable and wont shake while driving)
4. Run the halo wires to the inverter.
-If you paint the inside housing and are going to wire these up to your fog OR parking lights, you can mount the inverter inside the headlamp where canadian daytime running lights would go(use double sided tape). Then splice the + an - wires to the wires inside the housing. (either fog or parking lights)
-If you will be using an ON/OFF switch (so you can run them without any other lights) Lengthen the wires from each halo 12 to 18 inches and drill out the backside bulb housing (grey one for the main headlamp). Use a silocon caulk to seal it up. (allow some dry time for the caulk, otherwise it may cause moister inside the lamp) Then attach inverter to inside engine bay(outside of headlight).
5. Put Headlights back together using the oven method again.
6. Mount it to your max and Turn em on!


You still may want to reference to above instructions for Headlight removal.

I have found that using a Heat Gun will work instead of using the oven to get the sealant loose enough to pull them apart. (if you'd rather use the oven, see above)

Get a Heat Gun in your painting dept. of a Home Depot or Lowes about $30. You'll want to use it on 700degree F (with a heat gun only), not higher so make sure its got that setting.

Before you start heating, there are 2 screws on the back of your headlight assembly. (shown in pic #1) Remove these 2 screws
Pic 1
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Once screws are removed, remove all the wiring and bulbs. Set them aside.

Now its time to bake (see other sticky) or use your new heat gun.
***Be carefull not to scratch up your outer lens by moving it around on the table or lap. They scratch easy****

Start on one side on a setting of 700 (heat gun only, not oven)
Move it across about 1" every 5 second. Holding it about 3-5"s away from the headlight. Go over that side about 5 times, the test to see if it starts pulling apart. If it moves even slightly, try heating another side.
Repeat on all three sides till you can pull the clear lens off the housing.
Can take 10-20 minutes.

Once the lens comes off the housing you'll be left with this.

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There is 1 screw to remove that holds the center piece (the piece you'll attach the halos to) Remove this screw.

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Now your ready to MOD. Paint, install halos, clear amber sidemarker or add LEDs.

Put down some masking tape on the areas you need to drill into to mount and run the halo wires through.

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Once holes are drilled for the halo rings. Use your 2 part epoxy on the backside.
***Use epoxy sparingly. Too much will drip everywhere.****
Epoxy the backside of each hole and the backside top of each halo ring.

Backside Top Halo
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Backside Bottom Halo
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Now its time to place the power inverter. Put this inside the Canadian Daytime Running light space.
***If you mount inverter outside the headlight even the smallest drop of water on the connection will cause a short****
If your from Canada and have a bulb in here, you'll need to get creative and find an area in the grey cover behind the main bulb to mount them.

Picture below is taken after removing the chrome housing for fog and DRL. Not necessary to remove this, just done to show you'll be drilling through 2 pieces. This is where you will run your power wires through to hook up the power for the halos.

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You'll also need to drill a hole out the side of the DRL area for the halo rings to hook up to the inverter.

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Close up of them both.

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Attach black plugs to the wires of the rings. (look at the back of the black plug closely. You'll see there is a notch in the center of one side of the holes in the plugs for the wires to go into. When you look at the wire, you'll see a "snap lip" that lines up with that notch. When you push it in all the way it will snap into place and cannot be removed.


Now, its time to go in reverse order. Push the center piece (the one with the halos mounted) into the front, clear lens. Install its 1 screw that holds it into place.
Now, bring the clear lens and main housing together and plug in the connectors between the rings and the inverter.
If the rings wires get in the way of the main projector, you can usually get to them from the backside to move them from the Fog light area.

Now its time to heat up the sealant to make things come together. Put in oven like before (See 1st set of instructions)
Use your heat gun in the same way you did to take apart. Making the sealant soft, so you can push them together.
Work the heat around the outer edge of the housing and when it seems they are back together put in you 2 outer screws while the sealant is still soft.

Attach wire harnes and bulbs.

***Let it all cool down before you put the bulb covers on***
***If you painted your housing. You'll want to bake the painted piece (without halos installed) to get rid of all moisture. And wait 24 hrs before putting on the bulb covers.****

Wiring Halos to Parking Light

The Red+ and Black- wires out the backside of you headlight assembly need to be sealed so no moisture gets inside. I recomend purchasing "grommets"(they look like Orings, but have a slit all around the outer edge. Also, use silicone sealant or your 2part epoxy over this.

Splice the Red (+) wire to the Green/orange wire on the parking bulb harness.
Splice the Black (-) wire to the Blue wire on the parking bulb harness.

Anybody with questions feel free to pm Max Power.
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Old 08-29-2010, 12:34 PM   #2
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Default Re: How to Install Halos

Nice write-up
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