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post #1 of 9 (permalink) Old 05-04-2018, 09:39 PM Thread Starter
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Cool Some 1st gen love!!

Hey gang!! It's been a while since I've posted and I want to get back into it. I was looking on how to do a build thread built I guess I'll just do it here. I just post all of my progress past and present for my 03 6S. My baby girl is of age where I can start working on things and check in on her or she won't get into things while I'm working so I'm excited to get started. A little background of what I like to do is I make custom LED lighting for my vehicles when time and efforts permit. I will be doing a complete HID Retrofit along with building my own LED arrays to do LED retrofits as well. But not everything posted here will be all about lighting so..

I have a huge build in store for the front end and I'm still in the planing stages for the rear. I know exactly what I want the front to look and act(more on this later ). Maybe once I get the front done I'll have a better idea for the rear. I may do some things outside the box so please bare with me.

Here is a little something that I already have in hand and ready to start on
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Also had to give a slight preview of the new mesh going in. I will be installing the fog lights this weekend along with new mesh. While I have the front bumper off, I will be installing my HID harness, ballasts, and replacing the bulbs in both fog and low beams. This show improve my visibility drastically until I get all of the projectors ordered and in. When I do finally get to retrofit the headlights, all the ballasts will have already been ran and so I can just plug them in and be done.

The clear lenses in the pic I won't be able to use. I bought them but the reflector is in the lens vs the housing so one couldn't see any custom work inside of it. I'll order a new pair here shortly to cut open and build an array. I did get to do some testing on a new product (to me) that I will be using.

Here you can see that the reflective prism is in the lens.
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Side by side comparison of that light and some of my past work.
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With the new side markers that I will order having the reflector in the base of the housing, I needed to come up with a way to still have a reflector on the side. Started to look around on the net and found this Black Reflective tape. It's black during the day but shows up silver when light hits it.

No flash.
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With flash.
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I ran continuity test on the tape and it's non conducive so it was on to the next test.
kufliclicks likes this.

Ray.

2003 Mazda 6s
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post #2 of 9 (permalink) Old 05-04-2018, 10:10 PM Thread Starter
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With it passing the continuity test, it was time to go ahead and do a mounting test. For this test I just used a spare piece of lexan that I had laying around to mount the tape and LEDs to. I needed to see how well this would stick and look AFTER the heat of the LEDs being soldered.
I wanted to make sure that the tape would still stick as well as make sure that it would not deform while the heat was put to it during soldering.

These are the amber LEDs that I will be using. Cree amber P4s.
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All soldered up.
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I was happy with the outcome. The tape held up very well. It didn't lose any stickiness and it did not deform under the heat. 2 more test down!!

No flash with LEDs
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With flash with LEDs
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At this point I'm digging the tape but I still needed to see what it would do behind the lens and what it would look like once the LEDs were powered. I popped my little test board into an old clear housing from my old Eclipse for this next test. It was all "cross my fingers" at this point because if it didn't reflect right, I'd have to find something different to use.

Behind lens with no flash.
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Behind lens with flash.
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LET THERE BE POWER!!!
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This tape rocks for what I'm wanting to use it for. I will be using it just like in the test but on a board made for our cars . I had thought of other ways to use it just like the bikers have been on their bikes and helmets. It made me think of another test.. In this one I wanted to see what it would look like under a clear coat of paint directly on it. I took a small piece of it and stuck it to a piece of cardboard. I hit it with 3 coats of clear and let is dry.

No flash.
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Flash!!
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It looks great under the clear coat. Best of all it's sealed down to the cardboard now. This is nice to know for the future😎!

Ray.

2003 Mazda 6s
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post #3 of 9 (permalink) Old 05-07-2018, 09:39 AM
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Got yourself some good projects to work on. Keep it up and keep us updated on your progress - I'm sure everything will look great on your 6

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post #4 of 9 (permalink) Old 05-11-2018, 09:08 AM Thread Starter
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Quote:
Originally Posted by Byakuya View Post
Got yourself some good projects to work on. Keep it up and keep us updated on your progress - I'm sure everything will look great on your 6
Why yes I do lol. It's nice to be able to get back into making a car "mine". Slowly but surely it's getting there but have so much more planned. I will definitely keep this up to date.

Ray.

2003 Mazda 6s
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post #5 of 9 (permalink) Old 05-11-2018, 08:49 PM Thread Starter
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So on the past Saturday and Sunday I spent getting the car ready for the retrofit. I still need to order projectors but I had a light out anyway so why not get the wiring all done and out of the way. With the increase in the lighting, I still needed to do something the the lenses.

Here is the car at the beginning waiting for surgery lol. As you can see, my lights needed help.
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I took 3 HID harnesses and made them into 1 "main" harness. This harness will be just for the headlights. Slowly but surely I will be cutting the drivers side headlight plug out and will have the passengers side unplugged and capped off. All of my connections will be soldered and heatshrunk. I like knowing that it won't cause an issue later on while I was at it, I went ahead and ran the harness for the lower fogs that I had ordered just for the "sports" bumper.

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With the bulk of the harness ran, it's easy for me to fine tune the length of the wires. Then it was on to the lights. I spent about 1 hour on each light getting it ready for a clear coat. I wet sanded them starting with 400 and work all the way to 2000 grit. (No boring pics of it lol) Once done I hit them with a clear coat but it ended up wrinkled on me. I then spent another 2 hour wet sanding the lights down because of it smh. At this point I needed to stop on the lights and get the ballast mounted. I found the spot that the factory D2S ballast mount to on the bottom.

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This was just a quick and dirty adaptor that I made to fit the ballast. I will make another one later to hold the 3 ballast that are going to be going to the lights in the same location. I was getting rushed on time because I needed to be able to drive it. While I still had the bumper cover off, I figured I'd mount the fog lights and change out side markers. I then had to mount the new mesh. I tried to use the factory mounting tabs to hold it in place but this caused unwanted dents and cause it to look uneven. Good thing I bought 2 sheets

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I will let it ride like this until I get the projectors in for the retrofit. It still looks ok for the time being. It's still a work in progress so it's fine for now lol. It was time to just get her back together and on the ground. The next time I have the bumper off, it will be a much quicker ordeal. For the most part, I'm happy with what I got done on it over the weekend.

Here she is after the end of Sunday!

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35w 5500k H1s in the lows and halogens in both fogs...... for now

This is the beginning of the updated facelift.

Ray.

2003 Mazda 6s

Last edited by DJ Raydiate; 05-11-2018 at 08:52 PM. Reason: Spelling lol
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post #6 of 9 (permalink) Old 05-12-2018, 02:47 PM Thread Starter
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Today was a little different. Still giving it some love but more on the maintenance side of it. I need to do the valve cover gaskets but the engine bay was filthy. I needed to try and clean it up a bit before I do the gaskets due to 15 years of who knows what.

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I wasn't sure where I wanted to start on trying to clean this thing but one of the people I subscribe to on YouTube has a video of just that.
https://youtu.be/PRSoRkM8GcM
This guy is very informative about diy automotive. So with my supplies ready and knowing a plan of attack, it was time to get to it.
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After hours of cleaning, scrubbing, spraying, and using the air compressor, I was ok with a stopping point.
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With the engine in a better condition, I'll be ready to tackle the gaskets next weekend. I didn't want to get too involved with the car due to mothers day being tomorrow. Once I know the engine is better sealed I'll do a much deeper cleaning and detailing.

Ray.

2003 Mazda 6s
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post #7 of 9 (permalink) Old 05-15-2018, 10:02 PM Thread Starter
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Not much to update today other than the retrofit will be put on hold until fall. The reason for this is because I saw a short video preview of the new Morimoto mini D2s 5.0!!! By the looks of the short clip, these are going to blow the 4.0s out of the water. I'd be pissed if I had gotten the 4.0s next month and 3 months later the 5.0 comes out. Thankfully I follow TRS on Facebook and the vid showed up on my feed.

With that said, it just gives me more time to prep. I just ordered 35w 4500k H3Cs for the head fogs that I can install sometime this weekend. It also gives me a chance to get to the junkyard and grab some internals from some other headlamps as spares and work on mounting the LEDs to the Demon Eye boards. Hell at this point I can even rip the lights apart here and there and paint the bezels. By the time the 5.0s come out, hopefully all I would have to do is order them up, pop my lights open for the last time, install and boom, done! Of course that's in a perfect world

Ray.

2003 Mazda 6s
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post #8 of 9 (permalink) Old 05-21-2018, 02:39 PM Thread Starter
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LED fun!!

Well my plans for the weekend were a wash out. I had planned on doing the valve cover gaskets this weekend but it was a wet weekend here in Fl. Decided to work on the Demon eyes instead. This way the engine and I both stayed dry. If I would have started them 1st thing on Saturday morning, I could have had them done before it rained. But with my luck, it would have started raining as soon as I got all set up. It wasn't all a washout for being productive for the weekend.

With the weather being iffy, it was time to go ahead and get the Demon Eye boards built and ready for the retrofit. My plan for the front is to have demon eyes in each spot inside the headlights and the now the lower fogs. With the 2 projectors already there and the turn and high beam spots, why not. The high beam locations will be getting a set mini h1projectors and I'm not sure about the turn at this point. I do have a thought though

These boards were made out of electronic perfboard, Red 20ma superflux LEDs, 4 wire ribbon cable, and some resistors. With a prototype made up and working, time to mass produce lol.
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Each board consists of 2 sets of LEDs. One set ( 2 leds ) will be hooked up to a 3 position rocker switch hooked up in reverse. Basically I will have the center running to the led arrays ground. This will give me the ability to flip the switch up or down and pull inputs from 2 different sources and have the eyes act the way I want depending on the source it's on. The 2nd set will be hooked up at a later day. I don't want to give it all away right now

At this point all the boards were painted, soldered and reinforced to the solid core ribbon cable. I chose this cable for many reasons. It's compact and gave me the amount of connections that I needed. It also has a little bit of form memory to it which is perfect for fitting it in place and it staying. With all of this done, it was time to call it a day.
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Oh!!! Look what showed up in the mail. While working on the boards, my fog bulbs came in ( kind of ). I ordered 2 sets so I could have a spare set laying around but the seller only sent 1. Contacted him and he is sending the 2nd set this week. Morimoto XB 35w H3C 4.5k
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Come Sunday morning, all I had left to do was to make the transition from solid core ribbon cable to mutistrain flexible wire. With the leds be such a low current, I used some 22ga speaker wire. The ribbon cable is great for inside the headlights due to the fact that it doesn't have to move. The connection at the headlights need to be able to flex some due to the nature of having to be able to move the harness around. All connections were soldered and heatshrunk and the transition was made!!
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The only thing left for the boards to be 100% done is the connectors. I need to find and order some bare 4 pin JST connectors and pins. This way I can cut the ribbon cable and put the connectors in. By doing this, when I go to change or upgrade a board, it would be as simple as unplugging the the connectors and switching boards at their location. All of the wiring can stay inside the housing and I would not have to do any soldering for a simple board change.

Not a bad productive weekend towards the retrofit!!

Ray.

2003 Mazda 6s

Last edited by DJ Raydiate; 05-21-2018 at 07:44 PM.
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post #9 of 9 (permalink) Old 07-17-2018, 02:33 PM Thread Starter
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Hey everyone!! It's been almost 2 months since I've done anything to (or even drove) my car. It hit 180k even (I'll upload the pic later) and developed a misfire in #4 cylinder. I figured it had to have been the coils that I've had on the car for the 3 years that I've had it. I got them as a set of 6 on eBay for less than $40. 3 years and 30k miles didn't seem bad for eBay coils to me lol. Anyway got a new set of coils and plugs for her and did the front bank just to get rid of the misfire so I wasn't down a car. Sadly, this was not the case. After the quick change it still had a misfire on #4 .

Being discouraged and busy, I didn't look anymore into it. Finally had time this past weekend to take the plugs back out to have a better look. It seems as if the injector is not working in #4 . Not being able to hear it or test it without taking the car apart, I just ordered up a set of refurbished injectors that will be here Friday. While I'm at it, I'll be doing the rear plugs and coils, pcv valve, and upper and lower intake gaskets.

This should fix the issue and get it back on the road. I have so much in store for it and can't wait to drive it again. I've had to drive my wife's 2000 VW beetle

Ray.

2003 Mazda 6s

Last edited by DJ Raydiate; 07-17-2018 at 02:35 PM.
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