Custom Projector Headlights (revisited)
03-24-2008, 05:54 PM
#1
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St. Jude Donor '08
Custom Projector Headlights (revisited)
My custom projector headlights (while fully functional) Just never had the clean look I was seeking. This is mostly due to my inability to seal the Lexan lens to the housing and the fact that I decided to cut up the OEM housings to use as mounts. The modules aren't mounted very well and tend to bounce severely when i hit a bump.
The 3 part solution :
Part 1: Remove then entire reflector assembly and build a new mounting Frame out of Aluminum or steel Sheet metal.
Part 2: Mount modules on the FRONT instead of behind. (significantly reducing clearance issues
Part 3: Build Fiberglass "bucket" for both modules.
So far I've made a basic template for the frame. If I had known this method would have been so easy, I would have done the project with this method before. I Could have completed the frame but the jigsaw is currently out of blades.
Stay Tuned: I have a surprise for at the end of the install.
The 3 part solution :
Part 1: Remove then entire reflector assembly and build a new mounting Frame out of Aluminum or steel Sheet metal.
Part 2: Mount modules on the FRONT instead of behind. (significantly reducing clearance issues
Part 3: Build Fiberglass "bucket" for both modules.
So far I've made a basic template for the frame. If I had known this method would have been so easy, I would have done the project with this method before. I Could have completed the frame but the jigsaw is currently out of blades.
Stay Tuned: I have a surprise for at the end of the install.
and good luck!
03-25-2008, 10:48 PM
#3
Team Owner
If you can make some good looking headlights that don't stick up or have problems and provide good lighting, you can sell a bunch of them.
03-25-2008, 11:50 PM
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03-25-2008, 11:54 PM
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St. Jude Donor '08
Fair indeed. I should be able to get this as a "Kit" setup by the time i'm done with it. I just need to finalize a template and parts list to get a ballpark figure on price. Some people might want to go the Non-HID option since the D2S HID kits cost ~$200 and require customizing of the projector housing.
03-28-2008, 11:57 PM
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St. Jude Donor '08
template:
Test fit with sheet metal:
NO Clarence issues what so ever. With the modules installed it's easy to reach behind and remove the bulbs unlike earlier. I'm not completely satisfied with the length of the bent middle section and will probably make another frame with a longer mid-section. I will try to aim and fiberglass tomorrow.
I won't be able to paint until later this week due to crappy weather.
The surprise looks freaking cool.... but will have to wait until the finished pics.
Test fit with sheet metal:
NO Clarence issues what so ever. With the modules installed it's easy to reach behind and remove the bulbs unlike earlier. I'm not completely satisfied with the length of the bent middle section and will probably make another frame with a longer mid-section. I will try to aim and fiberglass tomorrow.
I won't be able to paint until later this week due to crappy weather.
The surprise looks freaking cool.... but will have to wait until the finished pics.
03-29-2008, 01:40 AM
#9
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as stated before, if the price is right, i would be EXTREMELY interested. i have also forwarded this a a couple of my buddies who would also be interested. keep us posted....and great work as always
04-01-2008, 01:15 PM
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St. Jude Donor '08
As you can see in the last picture, the low beam projector has both outside mounting tabs cut off. This was for clearance reasons in the original install, however the new installation needs at least 3 mounting points for the adjuster screws. I was able to grab a pair of "scrap" 90mm projector modules from the company I originally ordered from to use as parts for mine. I'm expecting them on thursday and if all goes well I can start the fiberglassing then as well.
04-02-2008, 12:15 AM
#13
Burning Brakes
hmm... good thing I haven't sealed mine yet. I want to see how this turns out. I'm not completely happy with how I mounted the TSX projectors in the stock housings.
04-02-2008, 10:43 AM
#15
Drifting
I'll be your 1st, non-you, guinea pig.
04-02-2008, 12:06 PM
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St. Jude Donor '08
One of these days, i'm going to get a more powerful cutting tool....other than a dremel. However it is nice to know that while it took 3 days and 4 attempts to get a satisfactory frame for the driver's side, it only took about 20 minutes to build the passenger side after i got the specs. 
04-03-2008, 11:15 PM
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St. Jude Donor '08
Night Shots:
They're aimed and all set to be fiberglassed tomorrow. I was worried about vibration in the headilghts but it's not nearly as bad as i thought. Above 70mph they jiggle a little, however the fiberglass will significantly reduce the vibration.
here's the bare minimum:
And a few shots of the pattern:
From the driver's window:
From the roof:
A little to the side:
Keep in mind, it's my driveway that's crooked....not the lights
They're aimed and all set to be fiberglassed tomorrow. I was worried about vibration in the headilghts but it's not nearly as bad as i thought. Above 70mph they jiggle a little, however the fiberglass will significantly reduce the vibration.
here's the bare minimum:
And a few shots of the pattern:
From the driver's window:
From the roof:
A little to the side:
Keep in mind, it's my driveway that's crooked....not the lights
04-03-2008, 11:25 PM
#19
Melting Slicks
looking good
can't wait to see the next step.
can't wait to see the next step.
04-04-2008, 04:21 AM
#20
Burning Brakes
Are you sure the vibration is from how you mounted the projectors? Mine vibrate a lot, but I can clearly see that every bit of it is caused by the arm mechanism. Someone on the forums opened his up and did something with the way the arm connects to the headlight housing and reduced all vibration. I plan on doing the same soon.