Projector Retro, It FINALLY stopped raining for 2 consecutive days! Options

[GriffGirl]

So I've been working towards this for a while, and I finally got the time and a dry weekend to complete my projector retrofit. This is my first time doing anything like this, so go easy on me! I used Rayme's lenses and his stickied How-To write-up for guidance. I took pix along the way sort of as an appendix to his write-up for those of us who do better with detailed visuals. I put clear lenses on all 4 headlights, but the pix below specifically pertain to the low beams, as the high beams is self explanatory.

Before:


Lense Removed from one of the low beams:


"Exploded view" of the components that make up the low beam internals:


Tiny stainless bowl of vegetable dip mix (!) and bathtub faucet ring for shroud and bezel use:


Cut out the bottom of the bowl for the lens to fit through:


Cut out the reflector to fit the back of the projector through - no turning back at this point!


Test fitting the projector. When I marked up the reflector to mount the projector, I removed the lens from the projector so I could make sure the cutoff shield was level. Then I test fit the projector in the reflector only, to make sure it bolted in correctly. Once I was sure that it was correct, I mounted the reflector back into the headlight bucket, tightened it in, and then drilled the projector mounting holes all the way through. By doing this, I'm able to adjust the alignment of the projector itself within the reflector.


Test-fitting the shroud I made. I had to cut a notch at the top of it to allow it to recess into the reflector without the glare shield mounting point obstructing it.


I also bent the bottom part of the shroud up to flatten it down some. The bent part doesn't show once it's in, but it allows the shroud to fit better into the reflector unit. I probably could have just cut this part out, but I wasn't sure how much of that would show, and I wanted to keep it as finished looking as possible.


Test fitting it over the mounted projector (still without the lens on it, so I didn't risk chipping or scratching the glass lens:


Mounting the shroud to the reflector unit. JDM, yo!


After.
This morning I learned that JB weld was a bad idea, as it doesn't bond metal to plastic well at all. Note the top part of the shroud on the passenger side. Now my celi has a lazy eye. Bummer. If I get home in time tonight, I will take it apart and figure out a plan B. It will probably involve using the mounting point where the glare shield went to screw the shroud to. The screw is small, and will probably not show at all, but we'll see.


Close-up of the driver's side. Other than the issue with the passenger shroud, I'm really happy with how they came out. Once I get the passenger side fixed, I will aim them and take night shots of the cutoff. It looks really good though and has nice color banding at the top.

[d0w0rkS0n]

wow! that looks so sexy!! great job griff!

[96bluevert]

nice work!

Props for originallity.

This post has been edited by 96bluevert: Apr 6, 2009 - 4:17 PM

[manphibian]

Great Job!!!!

I think you should keep the lazy eye! It looks hilarious

Seriously though, the drivers side looks great

[DEATH]

Holy fcukin sh*t - nice job Griffy
Now make me some

[njccmd2002]

rivets, that bonds well

[GriffGirl]

Yeah, I was thinking rivets

Holy fcukin sh*t - nice job Griffy
Now make me some

Dude... seriously, it took a LONG time and a lot of work. I can see why people charge a lot for this mod, not to mention the cost of the projectors themselves. Luckily I made nice friends with this mechanic guy who gave 'em to me for nothin'.

[dustin15brown]

they look good, how's the beam pattern?
Also, your highs aren't going to work nearly as well since those are just us oem lights with clear lenses. Just incase you didn't know!
I would suggest that you do do something to the shroud. it would be really easy to smooth them out and paint them to match. I did it with one set, but idk where they went.

[DEATH]

Yeah, I was thinking rivets

Holy fcukin sh*t - nice job Griffy
Now make me some

Dude... seriously, it took a LONG time and a lot of work. I can see why people charge a lot for this mod, not to mention the cost of the projectors themselves. Luckily I made nice friends with this mechanic guy who gave 'em to me for nothin'.

was just playing girl

[GriffGirl]

they look good, how's the beam pattern?
Also, your highs aren't going to work nearly as well since those are just us oem lights with clear lenses. Just incase you didn't know!
I would suggest that you do do something to the shroud. it would be really easy to smooth them out and paint them to match. I did it with one set, but idk where they went.

Beam pattern looks potentially great. I haven't aimed them yet, so they're kind of all over the place, at least when parked 2 feet from the garage LOL

About the shroud - by paint to match do you mean paint them to match the color of the body of my car? I thought about that. I also considered smoothing them out to blend them with the reflector - how though? I don't have a vacuum but is there another way?

How can I make the high beams better? (LOL - I should've asked these questions a week ago, huh.)

[richee3]

How can I make the high beams better? (LOL - I should've asked these questions a week ago, huh.)

Three letters: JDM!

Hahaha no, I'm just kidding. I was talking to Remy a few months ago about installing those lenses on my USDM housings. He said what happens is similar to a spotlight. The beam will be focused at one place instead of spread out. He told me they were still usable though.

The retrofit looks really good! I like it!!!

[dustin15brown]

they look good, how's the beam pattern?
Also, your highs aren't going to work nearly as well since those are just us oem lights with clear lenses. Just incase you didn't know!
I would suggest that you do do something to the shroud. it would be really easy to smooth them out and paint them to match. I did it with one set, but idk where they went.

Beam pattern looks potentially great. I haven't aimed them yet, so they're kind of all over the place, at least when parked 2 feet from the garage LOL

About the shroud - by paint to match do you mean paint them to match the color of the body of my car? I thought about that. I also considered smoothing them out to blend them with the reflector - how though? I don't have a vacuum but is there another way?

How can I make the high beams better? (LOL - I should've asked these questions a week ago, huh.)

hahahaha 'potentially great' I dig it
You dont need a vaccum to smooth it out. Just fiberglass, sand paper, primer, paint *of the car or maybe to match the housing* It shouldn't be too hard, but when I did it I was 16 and they looked like ass.
You can't make the high beams better from anything I know. They will indeed look like a spotlight and are still usable, just something I hated when I had them on my car so I bought JDM highbeams

[xs94st]

Awesome work griff..good sense of ingenuity =)

A+ on the drivers side! Good luck with the aiming and fixin the passenger side, you'll figure out something that will astonish us =P

[GriffGirl]

they look good, how's the beam pattern?
Also, your highs aren't going to work nearly as well since those are just us oem lights with clear lenses. Just incase you didn't know!
I would suggest that you do do something to the shroud. it would be really easy to smooth them out and paint them to match. I did it with one set, but idk where they went.

Beam pattern looks potentially great. I haven't aimed them yet, so they're kind of all over the place, at least when parked 2 feet from the garage LOL

About the shroud - by paint to match do you mean paint them to match the color of the body of my car? I thought about that. I also considered smoothing them out to blend them with the reflector - how though? I don't have a vacuum but is there another way?

How can I make the high beams better? (LOL - I should've asked these questions a week ago, huh.)

hahahaha 'potentially great' I dig it
You dont need a vaccum to smooth it out. Just fiberglass, sand paper, primer, paint *of the car or maybe to match the housing* It shouldn't be too hard, but when I did it I was 16 and they looked like ass.
You can't make the high beams better from anything I know. They will indeed look like a spotlight and are still usable, just something I hated when I had them on my car so I bought JDM highbeams

so what is the difference between JDM highs and USDM highs, is it the reflector?

[dustin15brown]

I would ASSUME so, but don't quote me on that

[GriffGirl]

When you molded the fiberglass to make the shrouds, did you use a form to mold it to, or how did you do it? (I've never done fiberglass but then again I'm willing to try it)

[SveNRG]

Respect for your work and originality. They look much better than original lights.
The lazy eye looks like this!


This post has been edited by SveNRG: Apr 7, 2009 - 4:05 PM

[GriffGirl]

Respect for your work and originality. They look much better than original lights.
The lazy eye looks like this!

Totally!

[trdproven]

looks good except for the lazy eye. Just my 2 cents, entire lens does not look complete. It really looks like you retro fitted it. Why don't you get the transition completed from the outer to inner and it'll look stock and great.

[Rayme]

Nice one girl, you made your research well !