I finaly got the time to get the pics up of my custom headlight. the cutoff is amazing and they light up the road!. All i ask is for no one to come in here and bash my thread up? Not too much to ask for. If u think what ive done is stupid or “illegal” dont say anything. Ill post pics and explain a bit then edit it and add more detail later.
-Devin
Start with making a frame. I used plywood and coat hangers.
Next step cover the frame in flease and staple it underneath and around the edges…play around with it pulling/stretching the flease until u find the shape u like most then staple it.
Theres a few pics of the projector headlamps i bought. They use H3 bulbs but their yellow/amber bulbs which ill be changing to hyper white.
Fiberglass and bondo the housings. I dont need to explain how to fiberglass/bondo.
Now i took some 18 or so gauge stainless stuff they use for the bottom of storm doors and cut it to cover my headlamps and seal them inside the housing. after that i used the stock eye lids/covers and cut them up then bent the sides out so that i could screw them into my plywood housing. I also fiberglassed the inside of the housing with just resin and hardener to seal/waterproof it and hopefully keep the plywood from possibly getting to the point where it will catch fire :shock: I gota fire extinguiser so ill be safe:D in teh case that would happen…which it wont.knock on wood
Enjoy guys…feel free to ask questons or add me to msn to talk. Im not going to be mass producing these…I may make another set if people are seriously interested and the price is right. The lights alone were just over $200. Take it ez
-Devin
Yeaa i ALLWAYS go threw there to see my buddys at CT or gf in that area. Thanks for the compliment! im really interested in how many people like and how many hate. I cant predict how many will hate/like with a bunch of the haters we have on SON :twisted: Take it ez
-Devin
just over 200 with tax for the lights(2 sets) 20 bux for a fiberglass repair kit at CT. small jug of bondo a couple square feet of plywood…some screws and random brackets. 1/2 the stuff i had laying around so all in all ill estimate…260. Its more of a time consuming job more than anything. i spend a good week working on them every single day from 6-9:30. I also used a welder which helped making the coathanger frame and the brackets to mount it to the chassis. When i saw those halo projectors or carbon fiber housings from raceon(which imo look weird) for 9582958 bucks…fukk it. Ill make my own which is the kinda guy i am. Im 18 too…so anyone can really do this.
-Devin
BLahh…metals harder to work with(lazy). The raceon carbonfiber housing is the one i dislike. I dont want to look it up im lazy. I sealed the plywood so it wont rott out all the joints were filled with wood glue then i put sum silicone on the insides. as for adjustment the lights have mounts that have slots(juust like foglights)…loosen the screws and turn the indivual headlamp left or right…you have two in each headlight to play with :shock: i like the outside one pointing strait and the insides pointing a bit more inwards. you also have up and down adjustment with the individual headlamps inside the enclosure. The holes in the housing are a bit bigger than they needed to be so i can adjust the headlamps in the housing. The brackets for the actual housing also have slots so simply loosen the screw adjust the housing up or down then tighten it. Ima smart nutt knowing that i need to be able to have adjustment. These headlamps do get hott to the point where having ur hand on it for a second after it being on for 15 minutes will burn you…stick a peice of plywood in the oven and see how hott it has to be to actually burn and ignite the plywood…the foglights sure wont get that hott. I dont kno what i could use over the fiberglass to disapate heat…a peice of sheet metal maybe… I spent days drawing and planning this thing out during school time doodling.
Btw im not argueing with you…u stated your concerns and im stating what i did to prevent this thing from screwing me over. The cutoff is AMAZING its like my dads TL with HID’s. I love it.
take it ez
-Devin
humm… i donno if its not as bright cuz of hte bulb. or not… but… if its not cuz of the bulb… then i donno if it was such a good idea…but hell… it looks good… :thumleft:
Prob…i noticed the yellow lights up the road and the lines on the road farr better than white. that popup is stock…I just cant wait till i can afford the other set of projectors and hyper white bulbs. I may also re wire it so only one light is on in each headlight…have a switch to turn on the 2nd bulb in each headlight.
-Devin
Cant afford the other set so i just threw one in the other side instead of running the custom lights on one side and stock on the other…When i buy the second set of lights ill be using them as highbeams…having two in each is too much attaction for me. And the bulbs are going to be changed to super white. These pics are before i finished…i still have to redo the drivers side eyelid cuz i was ghetto…the body lines dont line up on that side at all…and i have to trim a bit more metal off both eyelids to get them to flow with the lines of the hood. So what do you guys think? youve seen how bright they are, very good cutoffs and doesnt blind or cause much more glare than stock…Ill be out at a few west end meets when the seasons back.
-Devin
More Hottness you know you want a set. I need opinions on the bulbs…? keep them yellow or get the super white wannabe HID’s or settle for CT grade regular bulbs?
This is the comparison pic between CT grade bulb VS yellow(the bulbs that came with it)
Start with making a frame. I used plywood and coat hangers.
all the joints were filled with wood glue then i put sum silicone on the insides. as for adjustment the lights have mounts that have slots(juust like foglights)…loosen the screws and turn the indivual headlamp left or right…you have two in each headlight to play with :shock: i like the outside one pointing strait and the insides pointing a bit more inwards. you also have up and down adjustment with the individual headlamps inside the enclosure. The holes in the housing are a bit bigger than they needed to be so i can adjust the headlamps in the housing. The brackets for the actual housing also have slots so simply loosen the screw adjust the housing up or down then tighten it. Ima smart nutt knowing that i need to be able to have adjustment. These headlamps do get hott to the point where having ur hand on it for a second after it being on for 15 minutes will burn you…stick a peice of plywood in the oven and see how hott it has to be to actually burn and ignite the plywood…the foglights sure wont get that hott. I dont kno what i could use over the fiberglass to disapate heat…a peice of sheet metal maybe… I spent days drawing and planning this thing out during school time doodling.
