0TheRadioFlyer97

Lol, I still haven't figured out everything I've used.

When I finish them, I'll start a new thread with an overall summary and schematics. There are a few things that I could have done to make the project much easier if i had the proper tools.

For example, I would have ordered a sheet of 1/8" Aluminum and used a band saw to cut it, and fold it so that the headlight frame would be a single solid piece. Then I would have the edges tig welded. Nearly a week and a half was spend on trying to bond galvanized steel plates. This idea would have made fiberglassing significantly easier as well.

I have a friend in my corvette group that works at a body shop. I'm going to see if i can convince him to help me paint the fiberglass. I'd hate to put all this work into a project and have the paint look like poo.

NSTG8R

kinda my thought.

0TheRadioFlyer97

non pop up headlights cost nearly $250-300 for the main lenses alone! The cost of my project since the beginning was only ~$400. The catch here is that to build non-pop up headlights (which would be MUCH easier) would require the use of smaller projectors such as the Hella 50mm modules. Unfortionatly there is no halogen model for the High beams so your cost goes up dramatically:

Lens: $250
Low beams: :$243
High beam (xenon): $812
Low beam D2S xenon conversion: $120

that's over $1425 in optics alone!
add the cost of hardware, and the dookey smooth angel eyes, fiberglass and misc stuff and you're easily looking at $1500 for headlights...granted they would be the coolest headlights around, but I'll drop 1500 in the engine before I throw it at headlights.

YELLOHHH

Why not just use the same lamp for high and low beam? Since the low beam would be HID, you really wouldn't need the high beams all that often, and if you use them for high beam as well without cancelling the low beam, you would have plenty of light and save $449 in parts off the bat.

0TheRadioFlyer97

true, but that's still ~$1000 for headlights....which rivals the price for the BPP kit and is definatly more expensive than the depos.

Zilla

that looks great so far

jrprich

Nice work so far. You have talent

0TheRadioFlyer97

I spent the last couple of days sanding, re-glassing and sanding some more. The shape of the curve doesn't lend itself well to power sanding so it all had to be done by hand: 80gr, 120, 220gr, 360gr. Fun stuff but I got a good arm workout

I dropped them off at a friend's body shop for finishing/painting. I will start another thread to summarize the build log once they're finished/mounted.

AMGPilot

Cool

I will be looking for the new thread

Sportsdude

Nice work Do yo think the steel plate's weight will cause issues to the headlight gears? Looking forward to the finished project.

doje

Better put in the brass gears if you havn't already.

0TheRadioFlyer97

During initial testing, the weight did not seem to be a significant factor for the headlight motors.

Brass gears on one side so far.

FreddyG

Just found this thread and have to say that you did a Fantastic job on those lights!

You've got MAD SKILLZ!

Please keep us posted when you get them back!

NAVY08

I had a very similar idea a little ways back, I may just try it now

0TheRadioFlyer97

I've decided to make this thread the "master thread" but if you want to see the cliffnotes look here:
http://forums.corvetteforum.com/show...post1565285302

Here are All the pics for the final installation:

Back from the paint shop:


Installed:




The halos look awesome:








Headlights On:


Night Shot:




The back side:


Paint kudos go to Brocks Collision Repair. My Buddy Larry hooked me up with their in-house painter.

FreddyG

They turned out Absolutely SICK!!

Great job, and the thing that impresses me is that you took an idea in your head and followed through and made it work!

melange6

Can anyone point me in the right direction?

Thanks