I can see some advantageous to fixed C5R style headlights.

- Losing 9 lbs of weight from the car. I already have non-runflats, magnesium wheels and will be looking to purchase a Z06 Ti exhaust in the future. Add all of those mods together and it's almost 50 lbs of static weight reduction...and even more if you figure 20lbs is rotational.

- Automatic headlight feature with pop lights is really annoying to use. They pop up when you enter the garage or start the vehicle in the garage. Adjust the sensitivity down and they don't turn on when it's dark!

- Removes a common failure point in the C5 design. Gears are always wearing out, motors fail and other weird malfunctions.

Anyway, I was very close to buying the Depo projector headlights. Then, I read a post that talked about the common cracking that these lights develop. There are other manufactures, but paying $1,000 for headlights seems like the Corvette tax to me.

Questions:

Why causes the cover crack? Is it the heat from certain bulbs, heat from the sun, or weather/temperature changes? Will using a "colder" headlight from the beginning prevent them from cracking?

Can the cover simply be removed if it cracks or will this allow water into the design?

There are some projector headlights sold for the C5 that are exposed with no cover. Perhaps the exterior cover from the depot lights can be removed from the beginning?

Does anyone have these on a C5 that's frequently driven with the lights on? How long have you had them and have yours cracked?

 

Why causes the cover crack? Is it the heat from certain bulbs, heat from the sun, or weather/temperature changes? Will using a "colder" headlight from the beginning prevent them from cracking?

A: Depo Headlights use a plexiglass/acrylic material in their lens. It resists scratching but is prone to microfractures from quick and excessive heat changes (i.e. turning on headlights in very cold weather) and road debris. All halogen and xenon bulbs emit heat, however HID capsules dissapate heat more evenly and would be a better bet.
Can the cover simply be removed if it cracks or will this allow water into the design?

A: Cover makes it weatherproof, can't be removed without risking water damage
There are some projector headlights sold for the C5 that are exposed with no cover. Perhaps the exterior cover from the depot lights can be removed from the beginning?

A: These are very rare and expensive and i don't believe they're compatable with the Depos because of the projector size and location.
Does anyone have these on a C5 that's frequently driven with the lights on? How long have you had them and have yours cracked?

A: My SW lenses are made from Lexan and don't crack. Lexan however does scratch easily so i had my body shop throw a layer of hard clear coat on them when i had them painted to prevent scratches.

 

Maybe you don't have the option on your 2000, but on may 2003 I just set the lights to "manual" on the option list. They only go on (and pop up) when I turn them on.

I think one of the neat things about the C5 is the "no headlight" look during the day or when parked.

 

My headlights do allow you to turn the automatic headlights off, but what's the point of having twilight sentinel if you can't really use it?

I loved the auto headlights on my other GM car, but that had fixed headlights. If I passed under some dark shade (garage, carport, etc.), then the headlights would turn on, no big deal and barely noticeable. These are always popping up unnecessarily.

Looks aside (highly subjective), I can see why GM when with fixed headlights on the C6, especially with the number of headlight related problems common to previous Corvettes.

 

Thanks for the info! I suspected as much. Perhaps a 35 watt HID would prevent cracking?

What about drilling a "vent" in the base? Would that help?

I had a leaky headlight on a car that would fill up with water and blow out the bulb all the time. Instead of replacing the headlight I drilled a couple of small holes in the front to let the water drain. I drove around like that for years with no problems.