1993-1997 Camaro Morimoto mini D2S square retrofit

thingiverse

All necessary components for retrofitting a 1997 Camaro with HID headlights using Morimoto Mini D2S 3.0 square projectors and 35w ballasts are provided. Factory adjusters are used to aim the lights. An adjustment bracket is included, allowing you to space the header panel down and forward; one side of my car required this modification, while the other did not. The reason for this discrepancy remains unclear. The projector mount should be printed from ABS or a similar material, as PETg may not work well. I printed the light pipe cover, lens cover, and adjuster bracket from ABS, but used PETg for the light pipe, rear cover, and body mounts. Cutting templates are best created from PLA, and do not forget to label them. Installation on my car was relatively straightforward: assemble the springs to the projector mount using self-tapping screws. Then install the springs to the body mount after mounting the projectors, using a pliers and cotter pins. This can be tricky; holding the cutting template flat is essential for accurate alignment with the body mount. If desired, consider simplifying this process in future revisions. Light pipes require 10 3mm LEDs each, which necessitate basic knowledge of LED wiring. Other necessary components include: * A glass lens, 3/16" thick, cut to size by a local glass shop * Heat- and UV-stable sealant (polyurethane or silicone-based) * Nylon-insert locknuts in M5 x 0.8 mm and M6 x 1 mm sizes * Low-profile socket head screws (x20) and standard socket head screws (x16) * Extended-length springs with a compressed length of 2.5" and spring rate of about 7lbs * #12 self-tapping screws, 1" long * 1/8" cotter pins I recommend using brass or stainless steel hardware to ensure durability. This design has been refined over 1000 hours; please do not remove my name from the components list.