Res' headlight build (wip)

Res

Well-Known Member
Lifetime Premium Member
WIP =Work In Progress
(I take no responsibility if u damage something or do something that causes damage, use common sense when doing this, if you think something might break, stop and re-evaluate)

this is going to be slow coming as other bits of the car take more priority over a 2nd headlight build
but it will happen slowly but surely.

im going to lay it down for you guys like a DIY tute, so you can build something same or similar or just so u have the knowlege to tackle your own headlight build whatever your thinking of.

so i have been a bit bored of my projector retrofit setup, i have angel eye rings in it but they are blue (cos i was a young'n once) so i cant have them turned on cos its illegal as.
.: building a new set that have white angels and 4,300K bulbs for better visability, 8kK was fine for the visability but ive grown up, i want something white instead of the blue/green
i have been doing heaps of brainstorming and research into what i like on headlights, i have a fairly decent idea but i cant have it too solid a plan as everything depends on each other part fitting
fitting a vent large enuf for a CAI feed and having a projector aswell is a tight fit, not to mention having access to the bulb, keeping it water tight and solid, keeping it looking nice, and trying to make it look badass. hard things to balance

so here is what i have right now, the badass MK-1 projector build (keep in mind i built this very early in modding life so it have quite a few imperfections)
DSCF6215.jpg

DSCF6195.jpg


this is what MK-2 basis is hopefully going to be, everything inside will be black or Carbon fiber (cos if im doing this im going all out) and the projector ring will be the only silver thing
also im aiming to incorporate some other fancy features like an electroflurecent wire parker internal strip down the bottom of the case as the parker, and using a nice line of orange/amber leds for the indicator, for something different, but as i said everything is very dependant of if it can work with the other parts
DSCF6566-1.png



so first step~
*01; Taking the casing apart

(test fit ur headlight to make sure it fits in the oven without touching the walls or door)
1- pre-heat your oven to somewhere around the 160*C mark, i used 145*C but i think a smigen hotter would ahve been better
2- line a tray with an old towel or rag so that when the headlight is placed on tray it only touches the rag (this is to stop it melting to the metal tray, not sure if it will just would rather take precautions) SAFETY=> make sure the rag doesnt overhang the tray or get near the burner or element of the oven, this could cause a fire
3- put headlight in for approx. 1 and a 1/2 minutes on the rag tray
keep an eye on the headlight at all times, and be gentle as the headlight can snap- but also aggressive enough that it comes apart, its a fine balance
4- take headlight out, get flat head screw driver, and try to pry it appart slowly, it will be very hard to do, it takes a long time to get it apart
5- if it starts to get hard to work with (usually after 1-2mins of being out of the oven) then put it back in and heat it up again on the rag covered tray
6- repeat taking it out and prying and heating till it is apart, keep and eye out for internal screws as i think there are 2-3 in there, i broke mine while takign it apart :lol:
7- after its apart give it a good clean with soapy water and a brush, then a cloth after, try to get as much crap off it as you can (dont clean the bulb incase ur stupid and didnt know :roll: )

DSCF6904.jpg

DSCF6907.jpg

DSCF6909.jpg


* 02; sanding down the parts before paint (if ur going to paint that is)

so basically all parts you are going to paint you want as smooth as possible, use wet&dry sand paper (the finiest finish grit)

1- go outdoors this is a bit messy
2- grab a tiny bit of dishwashing liquid in a chinese container (about 1 med size droplet will be fine)
3- fill chinese container half with water
4- dip wet and dry in the solution and rub over the areas that you will be painting untill smooth
5- rinse the part as it will be mucky with all the particles sanded off
6- leave to dry

just something i found out while sanding, the silver part of the headlight shroud is actually transparent when its not painted
DSCF7051.jpg

DSCF7054.jpg

DSCF7064.jpg


thats all for now :wave: ~
still planning out the next bits, this is very much an exploritory build as this one is a bit way out there in the way of custom stuff
at the moment im waiting on funds to buy the projector setup to go inside and ironing out bugs of how i can fit both a vent and projector in the headlight
it will be quite a slow learning process but will hopefully turn out great results
 
so did a bit more on them, started cutting into them and planning and estimating everything
working out a route for the air to flow so that when the headlight is bolted up it isnt blocked by anything

some things i found out (i already had a good idea they would be problems but anyway)
~ battery needs to be relocated; something i wanted to do anyway, its going to go to the boot sometime before the headlight build is finished
~ the intake tract within the headlight will need to curve right into the headlight a bit so that the exit at the back of the headlight missed the radiator support and resovior bottle
and also so that the projectors light isnt blocked at all

okay so figured i'd show u some images that are sorta what im aiming for... they are audi headlights
images
images

so yeh, obviously my projectors wont be offset to the outer side of the casing like these (i would have liked to but it complicates things alot)
but i think you get the idea

anyway back to the process

i got a piece of PVC pipe i had lying around, this is acting as my projector cyl size, as its about the same size as one if not a little larger side which is good.
DSCF7065.jpg


this let me see how much clearance i have for the vent, so i marked out the vent area, its a bit small due to the nature of the headlight vent, but not too small, considering its a bit bigger than the OEM little funnel thing you have stock, and that the vent will be going a direct route right into the filter then into the plenum with as shortest pipe length as possible and 1 bend... i think i'll be right
so i marked out the vent main area and cut it out roughly (obviously be cleaned up later)
DSCF7067.jpg

DSCF7069.jpg

i cracked the reflector piece a bit... so thats being carbon fibered to fix it and make it badass, just going to go over it with black paint then 1-2 layers of CF cloth and resin for the *woo-hoo* and so i can learn to CF

see what i mean about battery relocate and clearance on the rad support+bottle
DSCF7076.jpg


so basically next step is to buy to projector cyinders and test fit them, then make everything fit as neatly arround them, then mock it up on cardboard, and fiberglass it for the shape, then work into that
 
looking good res. will watch ur headlight build closely not that i will be doing it but it looks to be handy information for the future
 
im on holidays from uni for for 4months... i need stuff to keep me occupied
and this is side project 2.
 
Res said:
im on holidays from uni for for 4months... i need stuff to keep me occupied
and this is side project 2.
u could work to get pay to have all the stuff u have setting in ur shed/workspace fitted to ur car res
 
lancer02ce said:
Res said:
im on holidays from uni for for 4months... i need stuff to keep me occupied
and this is side project 2.
u could work to get pay to have all the stuff u have setting in ur shed/workspace fitted to ur car res

im looking for jobs and the such, but so far no dice
owell just have to keep chugging along on $180 a week :roll:
 
will do, probably no updates till just after xmas tho, but i'll get on it after that

yes both hi and low
 
nice, what projector have you chosen?

Im currently in the middle of doing my custom one. Using a FX-R projector and the stock angel eye projector, going for the quad look.

I have thought about going for some strips of super flux amber leds for the indicators but havn't got far on my project.
 
crazyas said:
nice, what projector have you chosen?
Im currently in the middle of doing my custom one. Using a FX-R projector and the stock angel eye projector, going for the quad look.
I have thought about going for some strips of super flux amber leds for the indicators but havn't got far on my project.

projector cylinders,lenses,shouds,ccfls/ef-wire/led is all still yet to be decided
i have a too many options in consideration. choosing one will be one of ther harder decisions of the build as its the most costly part

i wanted to go quads, but just wasnt enough room with the vent,
so im either going one per case or might be putting a halogen hi-beam projector lamp in the drivers side where the vent is on the passengers so i can get a bit of warmth in the light for rainy/foggy driving

hows the kick on your (im assuming black aftermarket US CE projector headlights?) is it US spec or AU, that was a no deal point on them for me
also seeing as where u are setting the 2nd set in is hi-beams area, you cant go HID just an fyi incase u didnt know, you will have to find halogen projectors

as for leds, i recomend something not so spaced out, if u buy the generic strips they are crap, too much spacing between each led, you want them side by side like so;
http://www.ebay.com.au/itm/180556730267 ... 1438.l2649
 
Ah my angels are AU spec, even if they were US its a simple fix by making new shields. Tho i replaced my stock halogen projectors with the FX-R which are D2S HID bi-xenon with shields to suit AU. They are fantasic to drive with. I will be using the stock angels projector in the high beam area as probably just parkers or DRL's.

As for the amber indicators, i wont be using any strips as the usually fail quickly. I'll be using individual 5mm super flux leds placed in a line to make strips.

Just need to find a shroud for my 2nd set of projectors.

in the factory headlight you could easily fit 2x Mini H1 / D2S projectors :D I thought about getting a stock light and go tottally custom, but i've got the angels so thought might as well mod them.
 
well bit of action happened today
funds are tight coming to xmas, saving everything till after xmas i think, then parts will be bought

mocked up the vent divider today, good ol' cardboard and sticky tape
so thats the size of the vent sorted, just need to get some fiberglass stuff to put something solid there and cut out the back hole

DSCF7146.jpg

DSCF7148.jpg
 
lancer02ce said:
Joshy_morris said:
are u gona grind the inside corner out? hold seems a bit small?
doesn't need to be that big it is basically ramming air into his air box straight from the front.

not if hes sitting at the light waiting.
 
Back
Top