my projector headlight project

[apocalypse]

I got sick of the way my projectors were rigged in, so I got some fiberglass and started building

many hours later this is what I'm up to:

the projectors I have

everything is prepped, cloth is stretched and in place and I coated it with fiberglass

the shell before I cut away and put a layer of chop mat on it

both of the pods covered with chopmat and my (stupid and bad) idea of wrapping it with wax paper to keep the shape

after some sanding, grinding and cutting to make the headlight go down this is what it looks like

tomorow I'll be finishing up that one and cutting the holes and hopefully start on making the other one fit.Eventually, I'll bondo it and make them look prettier.More pics tomorow

[IveBeenBad]

should have used wood for the form and fleece for the shape

[Atomic-S14]

looks cool ~ hehe

[phuphyter]

I take it you're only using one projector per headlight?

what projectors are those anyway? hid? or halogen?

Keep us posted. Cool project!

[MAXIMUS Nismo]

looking good even though I don't know squat about fiberglass making/handling. Keep up the good work. And nice pics.
Modified by MAXIMUS Nismo at 9:25 AM 2/28/2005

[apocalypse]

I take it you're only using one projector per headlight?

what projectors are those anyway? hid? or halogen?

Keep us posted. Cool project!

I'm just using one per headlight, I don't have the extra money for the highbeams plus these are brighter than the highs were with the old sealed ones and I'm using the halogen ones

[Anand]

what kind of projectors are these???

[apocalypse]

heres what I ended up with tonight:

passenger headlight in and mountedagain one day I'll bondo it and smooth everything out and make it even



another shot from farther back

headlight on

farther back

thats all I got for tonightmore tomorow hopefully

I got the projectors from here http://www.rallylights.com/hella/90mm_modules.asp

[Atomic-S14]

would this setup give you enough lights for driving at night?is it hid?

[apocalypse]

the ones I have aern't HIDbut one of them on is brighter than the highbeams on the stock lights

[Anand]

looks great!

[Clatch]

Sweet! Have you tried out a high beam bulb in the projectors yet? Tell me if it works out, or if there is too much glare. I really want to do a double projector conversion per housing, instead of using the free form high beam and the projector low beam. Essentially just have projectors for both high and low beams.

[NSR240sxe]

Looks good so far. I'm curious to see what they will look like when they're completed. Keep us updated and good luck with the project

[kouki-gymkhana]

That would be easy to do actually. I have the Hella 90mm low and high units (2 per side) in my hatch and they work really well. You will come to realize why manufacturers don't install pop-up projectors on their vehicles when your lights start bouncing like crazy when you're on the highway, however

[Anand]

That would be easy to do actually. I have the Hella 90mm low and high units (2 per side) in my hatch and they work really well. You will come to realize why manufacturers don't install pop-up projectors on their vehicles when your lights start bouncing like crazy when you're on the highway, however

have any pics?

[slide240wayz]

High's and low's in one projector is called a bi-xenon projector. I give you mad props for the work, but all that just for driving lights?!?! If it is not to late, I suggest HID projectors, at least low beams, not even bi-xenon, but bi's would be even better.

Also how is the cutoff coming out? Remember you should have those aligned.

wishing you the best,Carlos Doria

[Clatch]

I have a question, since your doing a full pop-up instead of sleepy eyes, why didn't you just make a fiberglass copy of a sealed beam headlight? I would have just laid fiberglass over a sealed beam. That way I could just pop the headlight out and in of the meatal braket just like a regular headlight.

[apocalypse]

I wanted the headlight to still close and be better secured

[IveBeenBad]

I'm sorry, but that is one of the worst looking things I have ever seen.

[CybeRise]

oh man, that looks retarded. Sorry man, im just a bad a ricer as the next guy with my "RedSuns" sticker but....lol

[D Money]

i was planing on doing the same thing but with rectangular driving lights and sllepy eye converion. you should definatly make those lights lazier looking

[phuphyter]

That would be easy to do actually. I have the Hella 90mm low and high units (2 per side) in my hatch and they work really well. You will come to realize why manufacturers don't install pop-up projectors on their vehicles when your lights start bouncing like crazy when you're on the highway, however

Have any pics?

I kinda like this...ummm...probe I really like the headlights though. I wonder how he did them.

[wangless]

mmmm... fiberglass resin. i remember that STICKY stuff lol

looks kinda weird ?... full pop up with small projector. imo it wouldve been better with it half opened or something

[apocalypse]

i was planing on doing the same thing but with rectangular driving lights and sllepy eye converion. you should definatly make those lights lazier looking

I'm going to leave as it is for nowthey didn't quit turn out how I had invisioned but they work

hella is supposed to be introducing 50mm projectors next monthI'm going to wait for those get high and low beams and have a freind machine a plate the same size as the stock headlight

[phuphyter]

I'm going to leave as it is for nowthey didn't quit turn out how I had invisioned but they work

hella is supposed to be introducing 50mm projectors next monthI'm going to wait for those get high and low beams and have a freind machine a plate the same size as the stock headlight

I'm guessing you were trying to acheive that Ab Flug look? Too bad, I would've liked to see that on a 240.

You think your friend can make an extra pair if they work out?

[kouki-gymkhana]

have any pics?

Sure...Here's one.I upgraded to HID, BTW

PS: Don't ask for a step-by-step because I'm not going to volunteer that info. Too much $$$ and time invested for that ****...

[Atomic-S14]

looks nice... take some day time pictures and post em up too.

[phuphyter]

Oh yeah I remember your car and that post. I couldn't tell, but are your headlights a bit in the sleepy position? And what hid projectors did you upgrade to?

[Clatch]

I'm going to leave as it is for nowthey didn't quit turn out how I had invisioned but they work

hella is supposed to be introducing 50mm projectors next monthI'm going to wait for those get high and low beams and have a freind machine a plate the same size as the stock headlight

So Hella is coming out with a 50mm projector? In theory you could do triple projectors flush mounted right? I'm thinking of going JGTC style flush mount with a headlight cover using triple 50mm projectors then. Outside would be low beams, middle would be auxiliary beams, and inside would be high beams. Also projectors turned off would be emitted with a city light. What do you think?

OFFLOW BEAMSLOW BEAMS + AUXILIARY BEAMSHIGH BEAMS + ALL

[emperor_lunchbox]

kinda weird.... original though. I was trying to take a set of BMW headlights and try to fit those into a fiberglass form that sits a little recessed. but I had trouble with the first set of BMW lights and they were expensive so I might just go back to the drawing board.