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-   -   Porsche Headlight Retrofit [from CAD, prototyping to finish) (http://986forum.com/forums/diy-project-guides/48169-porsche-headlight-retrofit-%5B-cad-prototyping-finish.html)

rfuerst911sc 04-19-2014 12:52 PM

Hey particlewave are mine going to look like clickmans ? They look very nice ! Very close to my Artic silver and I went with the natural/gun metal grey. Can't wait to see them !

kjc2050 04-19-2014 01:12 PM

Quote:

Originally Posted by clickman (Post 396472)

Norm, that's one of the best treatments I've seen yet with Nine8Six's projectors - beautifully done. Congrats!!

clickman 04-19-2014 01:15 PM

To avoid any confusion, my car is Seal Grey, not silver. My crappy pic of the car buried in the garage doesn't help.

Fred's gunmetal grey shroud is an excellent match for it. Now that it's done, I almost wish I'd painted the reflector grey instead of black. On the other hand, having the projector "appear" or "emerge" out of the black is kinda cool...

clickman 04-19-2014 01:16 PM

Thanks for the positive feedback, guys!

:cheers:

davescott 04-19-2014 04:45 PM

Received the kit yesterday. You have some serious metalworking skills young man

Thank you very much

davescott 04-19-2014 04:58 PM

Excellent idea :cool::cool:

Quote:

Originally Posted by clickman (Post 396472)
Well, I'm finally done. After many trials and tribulations, the headlights are back in the car and I'm loving it. The improvement in the look of the car is immense. Fred's kit is awesome.

I sanded and painted the reflector, but opted to not paint the inner plastic shroud. I like it, but you can decide for yourself.

I wanted to do this project myself, so I was prepared for the warts that came as a result of being a rookie. For those that are ok with someone else doing the work and/or want it to be perfect, I highly recommend particlewave. Charles has it all figured out, and was extremely helpful to me with my questions through the process. And for what he charges, it's really a steal. Clearly it's more of a hobby for him, so get it while he's still interested!

http://986forum.com/forums/uploads01...1397921995.jpg

http://986forum.com/forums/uploads01...1397922062.jpg

http://986forum.com/forums/uploads01...1397922081.jpg


particlewave 04-19-2014 06:49 PM

Quote:

Originally Posted by rfuerst911sc (Post 396515)
Hey particlewave are mine going to look like clickmans ? They look very nice ! Very close to my Artic silver and I went with the natural/gun metal grey. Can't wait to see them !

This is just a mock up as I still need to clean and polish the inside of the outer lens since it is quite dirty and hazy, but the outsides have been cleaned up. Got rid of 95% of the yellowing and applied new UV coat ;)

Also still waiting on my relays to arrive. If they don't show up by tomorrow, I'll have to pay $$$ to buy them local. :(
Hoping to ship out 3 sets on Monday! :eek:

rfuerst911sc 04-20-2014 01:20 AM

Damn I like that ! I wanted a " stealth " look and this nails it great job thanks ! As I stated in PM's I am not in a hurry you don't have to incur additional cost on my account. I can wait until your relays come in. Your call.

Nine8Six 04-20-2014 05:53 AM

Quote:

Originally Posted by davescott (Post 396545)
Received the kit yesterday. You have some serious metalworking skills young man

Thank you very much

Just saw that Dave sorry. It got to be the best comment I've ever received... the "young man" part I mean ;)

You are welcome Sir. Was a pleasure

Few more ideas for your 996.... chk this out when you have a min (http://986forum.com/forums/general-discussions/51741-2014-porsche-carrera-cup-paddock-lots-pics.html).

BruceH 04-20-2014 06:32 AM

Quote:

Originally Posted by rfuerst911sc (Post 396582)
.........As I stated in PM's I am not in a hurry you don't have to incur additional cost on my account. I can wait until your relays come in. Your call.

Same here Charles, no worries:cheers:

tommy583 04-21-2014 06:53 PM

http://986forum.com/forums/uploads01...1398135100.jpg

First Ride with the new lights. Thanks Particlewave and Nine8Six :)

tommy583 04-21-2014 07:05 PM

http://986forum.com/forums/uploads01...1398135918.jpg

More of a front shot.

Nine8Six 04-21-2014 07:13 PM

Quote:

Originally Posted by tommy583 (Post 396899)
http://986forum.com/forums/uploads01...1398135100.jpg

First Ride with the new lights. Thanks Particlewave and Nine8Six :)

You, Sir, have ruined the only love I had left for my own boxster car lol

dream car right there (red interior). Mannnnn dunno what to say to you

particlewave 04-21-2014 07:59 PM

That is one fine looking ride you have there, Tommy! :D

I bet the new interior lights looks nice, too ;)
Personally, it was one of my favorite mods. It's really relaxing with all that soft blue light.

tommy583 04-21-2014 08:05 PM

http://986forum.com/forums/uploads01...1398139287.jpg

Oh yes the blue interior lights are so awesome. I had to get a new stereo just to match them :cheers: I will take a picture of them next time I get the car back out. Crappy and cold the rest of the week here :(. Here is a pic with the angel eyes lit.

Fred I would say your car is much cooler looking than mine!! But thanks!!

Nine8Six 04-21-2014 08:24 PM

Quote:

Originally Posted by tommy583 (Post 396918)
http://986forum.com/forums/uploads01...1398139287.jpg

Fred I would say your car is much cooler looking than mine!! But thanks!!

Don't get fooled by cheapo fiberglass. Mine is all good entertainment but as real porsche enthusiasts, we would all agree that a Boxster car equipped with a "genuine Porsche part aero kit" makes it one of the best out there (imo anyway). Proof above. I love this little roadster and I bet you can find previous posts on this forum where I've expressed my (personal) vision of a perfect Porsche car/color scheme. All the pics I've posted were silver color boxsters with "red" interiors.

I stared at your car here for about 10min sipping my coffee with a jealous look on my face.

honestly, thanks for the pics man. It is absolutely beautiful (looks so much younger now as well. Shocking lol)

Nine8Six 04-21-2014 08:27 PM

Angel eyes are sweet. Not stupid bright.... just enough to notice. Show car stuff.

Take good care of your car and its interior mate, lucky you

tommy583 04-22-2014 07:29 AM

Thanks Fred! I feel the same way about the factory aero kit 1. I think it makes the car look way more aggressive, yet still understated. The lights help bring out the beautiful lines of the car even more in my opinion. I can't thank you and particlewave enough!

rgriffin 04-22-2014 02:51 PM

Thank you Charles!!!
 
Here's a quick pic I took of my new headlights. They look better than I expected, and I can Finally see where I'm driving at night :) charles, you were awesome to deal with, and worked miracles on those old headlights to get them to look like this. I feel a renewed love for my boxster now! I can't t say thank you enough!
-Richard Griffin http://986forum.com/forums/uploads01...1398207077.jpg

particlewave 04-22-2014 06:21 PM

Thank you, Richard! :D

I received a $50 gift card from Richard today in thanks for doing the job for him. He really didn't have to do that, but it just speaks to the quality of people that occupy this forum.
Next week when I'm all caught up on retrofits and my girl isn't so busy with work, I'm going to take her out to dinner and have a nice quiet night. :)

http://i875.photobucket.com/albums/a...2709E1486D.jpg


Your car looks fantastic, by the way! :cool:

Nine8Six 04-22-2014 10:42 PM

Quote:

Originally Posted by rgriffin (Post 397077)
Here's a quick pic I took of my new headlights. They look better than I expected, and I can Finally see where I'm driving at night :) charles, you were awesome to deal with, and worked miracles on those old headlights to get them to look like this. I feel a renewed love for my boxster now! I can't t say thank you enough!
-Richard Griffin http://986forum.com/forums/uploads01...1398207077.jpg

Hi Richard

I didn't see the before and after but I can tell from your tone that you are very happy with what Chales did to them. I bet he added some UV protective coating to them as well. You couldn't have find better guy in the whole of the USA to restore those. Good on ya mate

The picture you took, that doesn't work tho sorry :p Let's see the front-end of your car on a overcast day or at sunset. Nice weather coming so no excuse for not detailing that deep black Boxster before a photo shoot :)

Thanks for confirming again that Charles "is the man".

Nine8Six 04-22-2014 10:46 PM

Quote:

Originally Posted by particlewave (Post 397119)
Thank you, Richard! :D
I received a $50 gift card from Richard today in thanks for doing the job for him. He really didn't have to do that, but it just speaks to the quality of people that occupy this forum.

You lucky bugger :/

RE "the quality of people that occupy this forum".

^^^ yep, and you Charles is ranking sky-high on that list. Nice work bro

particlewave 04-22-2014 10:59 PM

Quote:

Originally Posted by Nine8Six (Post 397162)
Hi Richard

I didn't see the before and after but I can tell from your tone that you are very happy with what Chales did to them. I bet he added some UV protective coating to them as well. You couldn't have find better guy in the whole of the USA to restore those.

I'm actually still quite the amateur at lens restoration. The inside of the lens is no problem because there's no coating and I can polish them quite easily. However, the outer lens has the UV coating which is very hard to get through. I have yet to find a method of removing the UV layer without causing deep scratches that take hours to wet sand out.

I appreciate the compliments, but I still have a long way to go. The only reason I did Richards was because they were in such bad shape that I could do no wrong.
I'll keep at it, though ;)

Here's a before shot of Richards. I hope you don't mind.

http://i875.photobucket.com/albums/a...200A576AB7.png

Nine8Six 04-22-2014 11:14 PM

I think I fully understand what Richard meant by 'miracle' now.

Geezz man... you just never stop to surprise

BruceH 04-23-2014 07:00 AM

Amateur?:rolleyes: You are too humble Charles, seriously nice work:cheers: Those before pictures are going to get you even more work!

N0tt0N 04-23-2014 07:45 AM

Quote:

Originally Posted by rgriffin (Post 397077)
They look better than I expected

ROTFLMAO. A bit of an understatement based on the before pictures! Classy acts you both are. Well done!

Time to start sending Particlewave worse and worse headlights. Maybe from the wrong car... I think I have some from an 1972 Opal Cadet. I'll tell him they are for an 02 Boxster and see what happens...

particlewave 04-23-2014 09:37 AM

Quote:

Originally Posted by N0tt0N (Post 397216)
ROTFLMAO. A bit of an understatement based on the before pictures! Classy acts you both are. Well done!

Time to start sending Particlewave worse and worse headlights. Maybe from the wrong car... I think I have some from an 1972 Opal Cadet. I'll tell him they are for an 02 Boxster and see what happens...

Hahaha! Funny stuff...

Relays are in, guys ;)

http://i875.photobucket.com/albums/a...FDE3AE5D8F.jpg

BruceH 04-23-2014 09:47 AM

Quote:

Originally Posted by particlewave (Post 397240)
Hahaha! Funny stuff...

Relays are in, guys ;)

Woo Hoo:dance:

nieuwhzn 04-23-2014 08:52 PM

Quote:

Originally Posted by particlewave (Post 397168)
I'm actually still quite the amateur at lens restoration. The inside of the lens is no problem because there's no coating and I can polish them quite easily. However, the outer lens has the UV coating which is very hard to get through. I have yet to find a method of removing the UV layer without causing deep scratches that take hours to wet sand out.

I appreciate the compliments, but I still have a long way to go. The only reason I did Richards was because they were in such bad shape that I could do no wrong.

My lenses were almost as bad as Richard's. Followed Fred's advice. Wet sand with 1200 grit until no yellow stuff comes off anymore. I didn't have any finer grit sand paper lying around, but rubbing two pieces of 1200 grit together takes their edge off enough to mimic a finer grit. Sanded with those until I didn't see any deep scratches anymore. Then used the step pads of a Turtle Wax Headlight Restorer Kit for a while. Finally used the polishing stuff that comes with that kit on a buffer with modest speed. Used spare amounts of polisher and just kept at it until happy with the result. The whole process is about 2 to 3 hours per headlight.

Btw, I see that Richard's rubber seals are as much turned into mush as mine. Any way to fix this?

Bbtw, what do you use for UV protection?

Nine8Six 04-23-2014 10:37 PM

Quote:

Originally Posted by nieuwhzn (Post 397306)
Btw, I see that Richard's rubber seals are as much turned into mush as mine. Any way to fix this?

I've retrofitted a Carrera a few months ago (3~4months) and use the below high density foam held by a few drops of rtv silicon. Still looking as new today. Not a perfect seal 'as rubber would do' but visually it is the same. Looks 100x times better than nothing at all or the old melted rubber anyway.

Not tested. I have no idea if this HD foam material will last "years" under heavy UV and sun heat. It is however definitely good to use as a quick replacement until you find a donor/oem rubber seal.

Everywhere on ebay in many sizes... $1 type item. DIY fun

http://i00.i.aliimg.com/img/pb/084/0...030084_704.jpg

particlewave 04-23-2014 11:04 PM

This stuff is a pretty good fit and is self adhesive ;)
Not perfect though...The fit is tight on the sides and loose up top.

Frost King E/O 5/16 in. x 1/4 in. x 17 ft. Rubber Weather-Strip Tape-V25BA at The Home Depot

particlewave 04-23-2014 11:08 PM

Quote:

Originally Posted by nieuwhzn (Post 397306)
My lenses were almost as bad as Richard's. Followed Fred's advice. Wet sand with 1200 grit until no yellow stuff comes off anymore. I didn't have any finer grit sand paper lying around, but rubbing two pieces of 1200 grit together takes their edge off enough to mimic a finer grit. Sanded with those until I didn't see any deep scratches anymore. Then used the step pads of a Turtle Wax Headlight Restorer Kit for a while. Finally used the polishing stuff that comes with that kit on a buffer with modest speed. Used spare amounts of polisher and just kept at it until happy with the result. The whole process is about 2 to 3 hours per headlight.

Btw, I see that Richard's rubber seals are as much turned into mush as mine. Any way to fix this?

Bbtw, what do you use for UV protection?

Opti-lens is good stuff...any clear coat with a good UV rating is better than nothing, though.

Nine8Six 04-23-2014 11:19 PM

Quote:

Originally Posted by particlewave (Post 397314)

The only reason I settle for the hd foam was to fight the 'fitting' issue. Tried some rubber seal but I just couldn't get the thing to 'squeeze' enough to fit the headlight in place. Those are normally industrial stiff :/ Tried smaller rubber seal but then.... worked just fine but no seal, water would have gone inside the fender like in the Niagara falls.

The HD foam made the fit so (too) easy, tight squeeze, perfect seal, no water and all but again.... not sure if the stuff will last years. I'm thinking NOT but we just never know

Nine8Six 04-23-2014 11:33 PM

Charles, if you still got some around take the measurement and I'll look around for it. Guessing this is made in my backyard here anyway so it shouldn't be hard to find.

Frost King lollll the name some gives to their products sometimes....

particlewave 04-23-2014 11:38 PM

To be honest, I have not actually tried it, but a few customers have. They said the same thing;
The fit is tight on the sides and loose up top.

This may require some garage R & D, lol :D

Nine8Six 04-23-2014 11:40 PM

I say srew it, finding the oem rubber from a dismantler of buy damaged headlight from a member is what needs to be done. Long term "fix" wise anyway

nieuwhzn 04-24-2014 09:04 PM

The crazy thing of course is that Porsche is not selling this seal separately from the rest of the assembly.
All these seals are turning into mush after a couple of years, so getting them from a dismantler or so just postpones the inevitable.
Fred, Charles, thanks for the suggestions. I think I have actually some of the Frost-King stuff lying around. I used it for its intended purpose, i.e. sealing doors and windows, but I was never very impressed with the quality. I'll get some of the high density foam.

rfuerst911sc 04-25-2014 10:27 AM

It is disturbing that Porsche does not have this headlight seal as a separate replaceable item. But as it turns out I know someone that makes aftermarket rubber seals ! He currently makes many Porsche seals for the older air cooled cars. I sent him an email asking if he would be interested in looking into making these and he said he is. But to do that he needs at the very least a small sample but preferably one complete seal. Does anyone have one they can give up for the R&D effort ? For my recently departed Porsche I had almost every seal he sells and they all fit and were of equal or better quality than OEM. I have no idea if this will come to fruition or not but it's worth a shot. I have nothing to gain from this just trying to help myself and the community. If anyone has a seal they can donate please send me a PM and we'll go from there. Should I post this anywhere else on this forum ?

particlewave 04-25-2014 10:32 AM

Richard,

I have one spare passenger side. It's a little gummy on one end, but it's all there.
By the way, I did not put your seals back on before shipping your headlights because they were pretty gummy and I didn't want to risk tearing them, so I'll just leave that to you. I included them in a separate Ziploc bag with the screws ;)

I'll send the spare seal to you on Monday.

rfuerst911sc 04-25-2014 10:55 AM

Great I may end up being the guinea pig for this development !


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