Particle do you think there is a difference between passenger and drivers side ? I would think they are universal.

Yes, they are exact mirror images of each other ;)

Interesting. Sounds like a group buy!

^ I'm in

Actually if the price is right I think take a few sets of those Richard (25~50). Thanks for looking into this mate, very kind

I have had several emails with the potential manufacturer and he's committed to doing the R&D once he receives the sample. My understanding of the process is first he will study the shape, going just on memory from when I sent mine to Charles there is a shape to these seals it's not like it's a giant o-ring. So a die or possibly multiple dies might be needed. Then the rubber type/compound will have to be determined, my goal is to have them made out of a compound that hopefully won't turn to mush. I know all of the seals I purchased from this vendor for my previous Porsche after 3 years were as good as when I installed them they weathered very well. The next item that will need to be determined is can he manufacture a complete one piece seal or will it be more like a rope and the end user has to glue the seam ? And finally after all this is determined what will the end user price be ? I'm already talking group buy we'll have to see what the min qty buy will be for him to cover tooling and first run costs. I'm cautiously optimistic this will become reality but we'll have to let it run it's course.
Charles/Fred any idea why the OEM seals turn to mush ? Is it the heat/UV from the sun or is it the wrong compound chosen by Porsche or ??? I want to provide as much tribal knowledge from the 986/996 community to the manufacturer to increase the possibility of getting these right the first time !

OK different subject I want to order clear corner lenses for my new headlights car is a 2002 S. Per Pelican Parts the part numbers 996-631-045-00-M422 ( left ) + 996-631-046-00-M422 ( right ) only fit model year 2003 - 2004 is that correct ? If it is correct what are the part numbers for a 2002 ? Or will they fit ? I want to verify before ordering. Thanks

I'm in as well! My FrostKing experiment is a decent temp fix, but I doubt will last for long. Nineapart quoted me $150/each plus shipping, but that was more than I was willing fork over.

They will fit. I believe the reason for the different model years is the earlier years had amber corners and the later clear.

Agree of letting this run its course. However if your friend is making these commercially, chances are he has those gigantic machines and presses. Seen those before... it is disturbing mate believe me. Our problem is min. qty to for him to break even (you can't say NO to a friend!). We'll need to buy min 500pcs of this small seal just so he can at least cover the cost of the energy required for heating his machine's rollers (used to melt the rubber). Molds cost are not included yet... those can go up nasty as well even if they are made of aluminum.

RE material; they will be most likely made of EPDM rubber. Or request for them to be (please :) )

The alternative:

Someone (Charles, you there?) to buy the casting kit and do them at home. Perfect for a small qty run. Doesn't require much to get this done in less than 48hrs (for someone that never done casting before). You just need a pint of casting silicon + catalyst and some modeling clay (plasticine?) to do a two-parts mold. Tutorials all over Youtube (I've just checked).

The rubber is also sold by the same sellers selling those DIY casting kits. They come in a liquid form with curing time ranging from 6 ~16hrs. Silicon rubber being one of the best and most used although not the cheapest. You can colour this stuff using plain dyes (black, gray, red, pink, whatever). Very high heat resistant... not sure about discoloration under UV however (might turn white, but after ten years).

Molding/Casting/Replicating a part is as easy as making a chocolate cake in all honesty. Today you can find resins in liquid form of any sort (silicon based, rubber, epoxies, acrylics, plastics, what else....)

Youtube "casting two part mold" type search. I've done a lot of that in the past (custom gaskets, o-rings, little plastic gears, anything really). Very fun and relaxing hobby

Thank you :cheers:

He has pulled off min buys of 50 on many items so lets see how this plays out.

Hey guys just letting you know I'm still alive :D and have not forgotten about the seals. Yesterday I received the sample seal from Charles and will be mailing it to the manufacturer for his analysis on how feasible it is to make these. As soon as I hear anything I will share with the community.

…last two pics, Porsche is mis-spelled.

Count me in. I'm also interested in a set of new rubber seal

Had a first run with the car and the headlights. I couldn't believe this :cheers:

Amazing kit Fred thanks

Wow Thanks for looking :) You are the only one who picked it up lol

Anyone tried painting the reflectors body color yet? If so, have pics?

One that I like very much is Norm's set-up:
(member Clickman)

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

But I think what you are asking is, is there any exotic colors out there. Not seen one yet although I have anodized a set of bezels in 'PINK' for a 996 based in Japan. Not going to upload pictures of this as I've been trying to find a way to forget about those ever since ;)

That is pretty exotic imo:
http://986forum.com/forums/uploads01...1400720153.jpg

You mention using high temp paint in your retrofit instructions, and recommend painting the underside of the housing. I have a can of factory match guards red paint, unfortunately it isn't high-temp paint. Does that section of the housing experience elevated temps as well? I've also heard the VHT red brake caliper paint is a near-perfect match - maybe I can use that if it is really a close enough match.

Hoping for a look something along the lines of the orange RUF you posted or this:http://986forum.com/forums/uploads01...1400777883.jpg

I'll give it a go and post the results when I get the kit in. If it really looks great, I'll have to upgrade to the custom bezels with a RUF script!

I'll be honest I've never bother to measure the temp inside the headlight. Not that it is complicated, just need a probe-style thermometer slipped in the high beam's socket. I am just assuming that being painted black, closed-envclosure, etc, it got to get hot in there on a day or two during the year (e.g. end of July, mid day, 105 degree, clear sky, headlight angled S-W) ouch! lol

Black is the only reason I would go for a reputable high temp spray paint. Yours will be red so temps will never reach those of black.

ps. The key really is the surface prep. I wet-sand the plastic with #600 and leave it in that rough condition for ultimate adhesion ;) Spray paints normally fill that grit just perfectly and leave a 98% near perfect finish/surface. Two coats is often enough. I also degrease the parts to be painted with a commercial degreaser + rinsed in cold distilled water. It's permanent

Quick update: The manufacturer has received the sample seal I sent and he is studying several ways to manufacture, it sounds like he will be able to make these but that's far from being official. Sounded like he may have a more precise reply in about a weeks time. I'm just trying to keep everyone in the loop as this progresses.

Thanks to both of you for giving this a go

Still interested in new head light seals. Mush is too weak to describe my currents seals.

I've asked this question before and received an answer but I want to ask it again. The OEM seals have two different part numbers, I'm assuming to designate left/right even though you can't buy them. But are the seals interchangeable ? A left will fit the right and right will fit the left ? The last time I asked the answer was yes they will fit either side. I just want to clarify that point as we move a little closer. At this point I don't know how exact/precise the new seals will be or will they be a little more " generic " and will easily fit either side ? Really just thinking out loud.

Amber color angel eyes pics
 

If the part# is different then this confirms the seals are L + R :/

While holding the seal stretched in your hands and flipping it 180 degree, if both sides radiuses are identical then they should be good to go on either left or right. Can't really recall or needed to tried. Surely someone who already have a seal in hand could confirm this quick

Meanwhile some "amber" angel eyes lit up with a half-full 9v batt. For those of you who wants to carry on the stock Porsche amber theme to the front-end ;)

Those look nicer at full 12 volts. Same color, just brighter a tad. Impossible to have a good close-up shot with LEDs at full brightness. 9v & low camera exposure does it! my photographyskills s*x lol

http://986forum.com/forums/uploads01/021401545590.jpg

http://986forum.com/forums/uploads01/011401545636.jpg

http://986forum.com/forums/uploads01/031401545778.jpg

^ entertainment. In the express delivery jet already and off to you Charles

me = amber nut
you = awesome :D

Without our TÜV I would instantly order those :rolleyes:

I've shipped a projector kit to one of your mate in Bankfurt (Frankfurt?) a few weeks ago. He got himself a spare headlight set locally for 150euro just for his retrofit. He puts back his stock shiners for the TUV checks ;)

an idea for you if you can find those... which I've been told are everywhere in Germany

The seals are mirror images of each other and are not interchangeable in OEM form.
However, this is due to the embedded plastic mount tabs that I mentioned to you before. If your guy cannot embed these plastic mount tabs (which I'm sure he can't) then they should be reversible or universal.

Whoa!!!
That's hot :cool:

Ok thats Niiice!! - Just sold Clear Lights to Tightbox- Good Luck these look awesome!

Had some email dialog last night with the supplier, he's thinking of using satoprene from what I gather it is a plasticised rubber compound ? I may have to send him both of my garbage seals so he has a left/right to model. We're one tiny step closer !

OK last night I had the first phone conversation with the potential manufacturer of the headlight seals. First off I learned that he makes all his own molds/tooling in house so that drastically decreases the price ( good thing ). Second in his opinion the reason the OEM seals turn to mush is he believes whoever is making the seals only partially cures the rubber because after partial cure the insertion of the plastic pieces takes place. In his opinion the partial cure is the problem and the heat from being in the sun turns the rubber to mush. Third and most interesting to me is the cost of the seals we talked about. I'm not ready to disclose yet but we talked " loose numbers " and if he can hit these numbers I think everyone will be very happy :D. Sorry for the tease but I don't want to put the cart before the horse. Also talking group buy , volume wholesale pricing etc. so we are moving forward slowly. Not sure when the next update will be but as soon as I hear something you all will know. And just for clarification I have no financial interest in this and I won't be running a group buy, I'm solely interested just to get a set of seals for my own car ! The way I " think " this will go down is once the seals are available I'll discuss with the manufacturer a group buy using his website. Maybe a special code or something so 986forum owners get a discount. I would provide the website link and everyone would be on their own after that. That's pretty much it for now. :cheers:

Thanks for following up!

Just read all the pages, this is going on my wish list. I like the ones Clickman got, with blue LEDs. I have a 2003 Seal Grey with factory Lits. Think these would be an upgrade and could sell the originals to pay for the upgrade. I assume the factory washers would work?

Nice work here all!

If one has factory Litronics would this modification be suitable; do these projectors out perform the stocks? What are the specs.?

I would imagine the aim/levelling feature would be toast along with the link to the suspension; is this feature addressed or needed by this new projector arrangement?
What the performance differences between old and new? Which are better?

Is it feasible to perform the cosmetic changes only, on stock Litronics?

Clickman's the 911 'round' look many have been looking for!

yes for the factory washer. Those are external and does not interfere with any of the install

Litronic is just a fancy marketing term created by Porsche. It's the same thing as a xenon or more accurately HID lighting systems.

Bi-xenon means the low and high beams are both HID lights. Where the Porsche Litronic only uses HID for low beam and halogen for high beam. Some who've compared both the CGT kit with the Lits have notice a major difference in sharpness of the beams. The bi-xenon CGT kit being by far better (of course!). As for intensity/brightness they are pretty similar (low-beam wise). One cost thousands (DOT approved), where the aftermarket performance bi-xenon projector kit cost $355. A sexy flavor of the CGT style theme is a bonus.

Specs: amazing, affordable, functional, performing well, stylish, easy-diy (you didn't need data I hope!?)
Leveling: oem leveling features remains the same after retrofit (using same allen/hex porsche tool)
Performance: Day & night difference. Not comparable to the old halogen system to be more precise lol
Lit cosmetic chg: never seen yet

Let me know if you have any Qs mate. Not a pro of-the-lights but getting there slowly ;)

I think the leveling he is talking about is the auto level feature, they adjust to the load of the vehicle when they are turned on.

Sorry, that was a pre-programmed answer. Might be promotional as well ;) I'm currently on a mission to exterminate old halogen systems on Porsche 9X6 cars by offering an affordable solution.

Bottom line is... Lits are fine as they are, great lighting and don't need any modifications. Getting a set of halogen in good condition and retrofitting those with a CGT kit is a better idea - as you plan doing. That's also what I'd recommend JayKay doing

Could you retrofit the CGT kit into the Lit light?

Yes. Requires removal of the litronic projector and lens assembly. 3 screws and the whole thing falls off. That assembly is then replaced with a custom 1.5mm thick back plate meant to accommodate the CGT kit. You get to keep the lit auto leveling thing and all.

http://i16.photobucket.com/albums/b4...DSC_0509-2.jpg
^ This is what the whole Lit low beam projector assembly sits on. Only 3 screws.

http://i16.photobucket.com/albums/b4...DSC_0502-2.jpg
^ custom back plate with same 3 screws bolt-pattern replaces what you see there. CGT kit mate on that same back plate, and off you go.

Easy to do but then how many would do this to their beloved $2k litronics kit!

(ps. photos have been stolen from another site. Sorry!).

(Source: HOW TO: Make your Litronic Xenon [ Cut Off Line ] SHARPER !!! PICTURES !!! - 6speedonline.com Forums)