HID Bulbs & Headlight Housing

GrimJack

GrimJack

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I'm not sure I follow... Which parts are you talking about having to modify?

- There is the headlight itself.
- Behind that is the steel aiming basket.
- Behind that is the composite popup assembly that bolts to...
- ... the steel radiator support running across the engine bay.

Are you talking about just modifying the steel aiming basket?

I can take some pictures of the various parts if you don't have any already on hand and disassembled...
 
PureDrifter

PureDrifter

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Poodles;1673163 said:
OK guys. I think I can make them in such a way that you wouldn't have to cut anything major (maybe a little grinding on the plastic bracket piece behind the headlight), but it requires special bulbs. Going with normal bulbs looks like you'll have to notch the metal bracket behind the headlights that bolts to the core support.

As I'm going to be making them to sell, input would be appreciated :D
Click to expand...

sounds good but are you going to have a new bulb type designed or are you going to require a specific HID conversion bulb?

what projectors do you plan on using?

and if you need any testers.... ;)
 
Poodles

Poodles

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GrimJack;1673170 said:
I'm not sure I follow... Which parts are you talking about having to modify?

- There is the headlight itself.
- Behind that is the steel aiming basket.
- Behind that is the composite popup assembly that bolts to...
- The metal support brace that holds the hinge for the headlight assembly as well as the motor that bolts to...
- ... the steel radiator support running across the engine bay.

Are you talking about just modifying the steel aiming basket?

I can take some pictures of the various parts if you don't have any already on hand and disassembled...
Click to expand...

Fixed that for yah :D But yeah, might have to notch the metal piece that holds the hinge of the headlight assembly. If it's not enough, might have to notch the radiator support under it, but doubt it. More than likely will need to cut/grind a bit on the composite section (it's fiberglass reinforced plastic, so be careful!)

I actually have the ENTIRE assembly out of the car in pieces, just need to get pics.

The "special bulb" is a D2H. Basicly a D2S bulb with AMP connectors instead of the D2S connector which will save about a half inch off the back of the assembly. I'm trying to stay with normal D2S bulbs though since you'll be able to find replacements for years (or decades) to come.

Projectors, well, that would be telling now wouldn't it :p

The other issue is cable length on the ballasts, will 11" be enough...
 
Poodles

Poodles

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Parts are ordered, just gotta find which housings will be easiest to work with. Apparently some of the ebay housings are epoxied together instead of using a hot melt glue, meaning they'll have to be cut apart instead of baked apart (not good).
 
Poodles

Poodles

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Interesting that they're that expensive and all plastic. Though plastic tends to be better for projectors (doesn't distort the beam pattern so the the cutoff stays sharp), it's also less durable.

Looking into them though...
 
Poodles

Poodles

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Still waiting on parts (figures some stuff was on backorder). Anyone have a preferance for plastic or glass fronts? Glass distorts the beam a bit making the cutoff fuzzy, but they're cheaper and more durable. Plastic doesn't distort the beam as much but they age (might not be a big issue as we have popups).

Looking for feedback :D
 
Poodles

Poodles

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917mgte;1679525 said:
I was actually looking for housing and projectors and i just so happen to stumble across some 7x6 projectors. Saved me some time and they have a good cut off line... http://norcalmr2.com/pegasus/
Click to expand...

Low beam only, they're halogen projectors so they lack width, and they use a rebased bulb instead of a true D2S bulb. Their output looks crappy as hell too, reminds me of the super cheap chinese projectors... Plus they have no shrouds.

Only thing I like is the rear housing looks molded with standoffs to bolt the projector in.
 
Poodles

Poodles

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Well, projectors and stuff are in, just missing the housings. Hate dealing with people on ebay, they send the item out when they want to...
 
Poodles

Poodles

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You mean heat sealed and not glued ;)

Glued you have to cut, heat sealed you can use an oven to loosen and pry apart. As there are literally dozens of different headlights on ebay, it's hard to say which ones will work for this. I know the Pilot ones come apart easily, but the lense is plastic (good for beam pattern, bad for durability).
 
PureDrifter

PureDrifter

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sorry i meant silicone-based heat-sensitive glue vs. thermoplastic heat seal (ie-giant plastic crimper)

but yeah,you got the point. pilot ehh...hmm.. would love a glass one for durability but if plastic = easy open+easy seal....
 
Poodles

Poodles

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UPDATE: Coming along nicely. Will more than likely have to pain the reflector on the housing on this one since the chrome is so cheap that some of it came off when I peeled the low tack blue painter's tape off. I even stuck it to my shirt first! This one is about halfwa done, most of the cutting is done, it's just sort of mocked up at this point. Comments are welcome.
p1688221_1.jpg
 
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