That's it! The JWMobile is wanting this design.

 

Getting there, Michael! IMHO the gap around each light is bigger than it needs to be. 1/8" max should suffice if molded to a pre-aligned set of lights. It should only take a couple of millimeters of adjustment up and down to zero in the alignment. Left and right is predetermined and should require next to 0° adjustment.

 

As soon as you get it ready to ship - I am buying

 

Nice. Now make it out of CF.

 

Looks like my HALOs will look perfect on those. Carbon Fiber is really going to finish them off! Great job Michael.

 

perfect

 

How is that going to work if the alignment that they are molded to is different than the way i have mine aligned already. It was hard enough getting it right the first time, i'd hate to have to do it all over.

 

I think there are fit and build differences and I suspect there are different combinations of the stock adjusters and of the individual light adjusters that will yield an acceptable alignment. I think you've probably got it right leaving some wiggle room.

 

With the lights centered in their openings (sans shrouds) and aligned straight ahead, these lights' positioning should not vary from one car to another. Because ride height varies from one to another, only a small amount of vertical adjustment is necessary. Keep in mind that a couple of millimeters of adjustment at the lights results in a few inches at 25 feet, and several inches at further distances. It doesn't take much to zero-in these lights.
The original thought of the turtlenecks encircling the projector bezels with an equal gap around them would then allow the lights to be moved fore/aft within the openings to yield the desired "fit". I believe we expected these lights to be aligned without the shrouds in place, so excessive gap around the openings isn't necessary as far adjustments go.
That's how I initially envisioned these working, but the reality of the current design is what matters at this point. I'm sure we're all anxious to get these on our cars, so I'll say no more until we have them in hand.
Carry on, Michael!

 

Looking good, Michael! And, I agree - less clearance is desireable, esthetically. Funny that you had to resort to completing these on your own but, doesn't surprise me you did it better and faster.

Nice work!

Ed

 

Thank you Sir.

 

Gary, and thanks!
Would you be interested in helping me with the prototype fitting? Mapquest has you at reasonable road trip distance from me and I'm willing to make the drive to ensure these fit your halos and adjustment...

 

Copy That!!

 

Good man.

 

Jim, I can absolutely relate to not wanting to mess with it after getting it set.
I'm inclined to agree somewhat with c5vetteguy that your adjustment can't be too dissimilar from others and after going back and looking at the pics of your installation, I think we'll be ok.
If not, we'll fix it bradda...

 

Thanks James!
Your input has been awesome!

 

Thanks for ALL your effort and input Mike(!) and I agree with you to a point. I will refine the opening a bit more and work the gap down to aprox 1/4", as I think 1/8" might be a bit tight getting the finished shroud into place and still accomodate the halo's JW, Gary and a couple others have added.
I'm currently having a little difficulty getting this rigid model installed in place do to clearances.
Picture if you can, back when we had the old OEM headlamps (seems so long ago for me...) the technique it took to install the OEM shroud, tipping the top away from the headlamp and sort of inserting the bottom between the bumper and headlight housing, then rotating the shroud back to vertical and into the recesses in the lid.
Similarly, I think if the outer openings around the projectors were close to flush with the end of the bezels/lens' (similar to the OEM) then we could almost close the gaps up entirely. However because we want to leave some of the projector bezel exposed, requiring sliding the openings over the projector bezels (and even more so with halo's), I feel a bigger gap would better allow us to easily remove and install the shroud into the much narrower (than OEM) headlight opening.
I think the rigid nature of the molds I'm working with are helping me better refine this prior to laying up the first prototype...

All this said , please don't hold your comments my friend, I value them more than you might realize.

 

Great to hear from you Ed!
Funny you mention that and thanks for noticing.
I'm certain that you (and for that matter most people...) understand that sometimes you just need to step away from a frustrating situation or project for a clearer perspective...
Certainly the case here.

Was hoping to hear from "dquag's" and "t-bro" too, regardless thanks to all for timely input, comments and a prime opportunity to bump my post count...
More this weekend when the weather warms a bit here...

 

Just a quick note Mike :

I've been keeping current on what you're doing (nice work) but have been withholding my comments because it looks like I'm going to sell the C5 (long story, nothing wrong here, just looking to move to a newer crossover that better suits our needs). Didn't seem right to offer what I'd like to see when I'm not going to be a user.

I'll still be on the forum...and....Im not ignoring you

I'm returning the car to stock prior to trading it in if it doesn't sell before I want to get the new car so I'll be selling the lights (which kills me....love these things ) either with the car or in the parts section here. Ill put the new guy in touch with you when that happens.

You've been a gem to deal with, thank you.

Thats enough reading....now get back to work

 

another vote here for "less clearance is desirable for aesthetics".

good progress.