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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)

particlewave 07-24-2014 09:36 AM

I'm on it! Just been swamped! :)

Nine8Six 07-24-2014 10:26 AM

Standby for now!

If you have a minute dig out what Hubert's car looks like and made of. He is big & fast enough to figure out a way out of this with the pro in NL (Retrofitlabs). I'll go check these guys out see what they do there.

That is H's 3.6L BOXSTER (wroom wroom!)

http://s2.postimg.org/m0e87zxnd/1410...2b1f7a7e_o.jpg

Edreamsz 07-24-2014 12:29 PM

Guys, thanks a lot for your help! It's really nice to so how people can help you from the other side of the world :)

I'll receive a different set of ballasts hopefully tomorrow and test them one by one (Left then Right, and the together). Let's hope that that solves it.

I will also wash the car and post some new pics. With the pole position seats and my GT3 Cup front bumper! :dance:

batshapedheart 07-24-2014 06:51 PM

Did my car just TURN allergic?
 
Quote:

Originally Posted by Edreamsz (Post 411097)
Guys, can someone help me?

I have been having some electrical problems with the headlights. They work perfect BUT have some side effects:

My low oil warning light goes off. Turning of the lights and starting the car again solves that problem.
My battery light goes off. Turning of the lights and starting the car again solves that problem.
My automatic spoiler quits being automatic. Turning off the lights solves that also.

So, can anyone help me with the above mentioned? My battery is still strong. The car starts perfectly every time (even after a 3 week vacation).


I got the MK2 set (Same a Chrono's) and it hasn't given me a problem until now. Same as you: battery light coming on, oil light coming on, finding my spoiler up for no reason.
Could it be somewhat related to some of the LEDs dying out?
I can't think my car TURNED allergic to aftermarket kits after running with since last November.

Nine8Six 07-24-2014 08:18 PM

When you say MK2 set, are you making reference to the headlight below?

http://986forum.com/forums/uploads01...1332728343.jpg

Nine8Six 07-24-2014 10:14 PM

Quote:

Originally Posted by Nine8Six (Post 411431)
When you say MK2 set, are you making reference to the headlight below?

Answered my own question by looking up some of your previous posts. Looks like those are the headlights you have!

You could do like a few have done already and sort the issue by patching things up e.g. adding some resistance onto the light circuit. Problem remains? no worries just add more but not too much or you'll see your brightness diminishing greatly (dimmed headlights?) and those resistors' temp rising :/ Needs trials. If really that issue you are having doesn't want to go away, then you'll need to completely isolate the lighting system from the existing car circuit by connecting everything directly onto the 12v battery using a relay/harness type setup.

You could also buy a new battery, an alternator, and all should get back to normal same as the other thousand of boxsters/996s out there who are also equipped with the same headlights you have. Or HID kits!?

But again, I'm not a electro pro. Just a wild guess yea

BFeller 07-25-2014 04:07 AM

My question for all of this (tossing a rock in the dark) some folks had weird issues with the Litronics pop up in another thread. They would not self level, etc etc. It appears to have been fixed by replacing a particular relay. Does that relay exist in the non litronic cars, if so could one be effecting the projector lights in this case?

Nine8Six 07-25-2014 07:15 AM

Quote:

Originally Posted by BFeller (Post 411453)
My question for all of this (tossing a rock in the dark) some folks had weird issues with the Litronics pop up in another thread. They would not self level, etc etc. It appears to have been fixed by replacing a particular relay. Does that relay exist in the non litronic cars, if so could one be effecting the projector lights in this case?

Our friend Hubert will sort his issue no worries bro, nice of you reaching and trying to help out. The truth is, often simply changing ballasts with ones that has higher rated capacitors/resistance solves those weird problems. Trouble is you need to try a few and that can be annoying, or you might get lucky and the first one you try is spot-on (Hubert, fingers crossed).

-or- other similar patches to fix old car's fluctuating and/or weakening voltages includes adding "aftermarket" resistor & high power capacitor packs. Or even simpler, moving your high powered lighting system away from that car system and feed it directly from the 12v battery with a relay/harness. Cheaper than slamming in new batteries and alternators for sure (read I'd do the patching thing also lol).

Smallblock454 07-25-2014 08:18 AM

Quote:

Originally Posted by Nine8Six (Post 411368)

WOW! That car looks great!

Would do the headlight mod too, but the german TÜV won't give his OK for that. No chance to make such mods road legal in germany.

Regards

batshapedheart 07-25-2014 09:12 AM

Quote:

Originally Posted by Nine8Six (Post 411431)
When you say MK2 set, are you making reference to the headlight below?

http://986forum.com/forums/uploads01...1332728343.jpg

Yes, those very ones

Nine8Six 07-25-2014 09:34 AM

Quote:

Originally Posted by batshapedheart (Post 411497)
Yes, those very ones

Yea those are great looking headlights. I like them very much

You can buy a them here:
Porsche 986 Boxster 996 MK1 Black LED DRL Projector Headlights | eBay

ps. sure you can find other members here who has them, run a quick search?

Happy boxster'ing!

cbbepop 07-25-2014 07:46 PM

can you fit projectors into the fog light area on the headlight?

particlewave 07-25-2014 08:05 PM

The fog light reflector is only 4cm tall, so it would have to be a tiny projector. I have not had any luck finding any that small.

http://i875.photobucket.com/albums/a...415E5C6872.jpg

batshapedheart 07-25-2014 08:29 PM

Quote:

Originally Posted by Nine8Six (Post 411502)
Yea those are great looking headlights. I like them very much

You can buy a them here:
Porsche 986 Boxster 996 MK1 Black LED DRL Projector Headlights | eBay

ps. sure you can find other members here who has them, run a quick search?

Happy boxster'ing!

?!

Yes, they are very good looking ones: I OWN THEM. That's why I'm puzzled as to why my Boxster has "become" allergic to it: my battery and oil light are going off, and it's even affecting my spoiler.
So again, my question is: How could my Boxster have become allergic to it if I've had them since October and if its probable that a couple of LEDs dying would be the cause, since I also have LED taillights. I read somewhere that if you have too many LEDs that might trigger some issues, or something along those lines.

particlewave 07-25-2014 08:42 PM

It's not the LEDs. They are on load resistors, so even if all but 1 went out, the car would never know the difference (the resistor emulates a bulb).

Are you running halogens or HIDs in the units? What type of ballasts are you using, if HID?

Edit: my best guess is that you are also running HIDs and that this problem is being caused by AC feedback in the line from a faulty ballast.

Nine8Six 07-25-2014 08:51 PM

Quote:

Originally Posted by batshapedheart (Post 411589)
?!

Yes, they are very good looking ones: I OWN THEM. That's why I'm puzzled as to why my Boxster has "become" allergic to it: my battery and oil light are going off, and it's even affecting my spoiler.
So again, my question is: How could my Boxster have become allergic to it if I've had them since October and if its probable that a couple of LEDs dying would be the cause, since I also have LED taillights. I read somewhere that if you have too many LEDs that might trigger some issues, or something along those lines.

yea those are great looking headlights, one of these days I'll own them as well for sure!

If you have a battery light coming up, your twin spoiler motors and some other sensors doesn't have enough juice left from the car system to operate correctly, buy this mate:

Alternator:
Porsche Boxster (1997-2004) - Charging System & Battery - Page 1

Battery:
Porsche Boxster (1997-2004) - Charging System & Battery - Page 1

particlewave 07-26-2014 01:28 PM

Because the symptoms are the same as Hubert's, I wonder if bat is running HIDs...?

I'm leaning toward faulty ballasts as the cause, but hard to tell without concrete evidence or information.

Nine8Six 07-26-2014 06:52 PM

Quote:

Originally Posted by particlewave (Post 411648)
Because the symptoms are the same as Hubert's, I wonder if bat is running HIDs...?

I'm leaning toward faulty ballasts as the cause, but hard to tell without concrete evidence or information.

We've taken this up in the correct thread Charles. Thanks for your apocalyptic assumption btw lol 20,000volts AC feedback into the system.... you watch Preppers (Nat Geo HD, 21:00)?

Here the follow-up link for our friend Bat: http://986forum.com/forums/general-discussions/53288-freaking-out.html

particlewave 07-26-2014 09:04 PM

Hahaha! Good stuff, buddy :D

http://i875.photobucket.com/albums/a...597C2F1B6D.jpg

Edreamsz 07-29-2014 12:56 AM

Hi guys, here's an update.

Yesterday I received a pair of ballast with a build-in Canbus solution (ballast/starter/Canbus in one box). I turned the Xenon kit on and immediately my oil warning lamp went on :mad:.

So, these units are going back. My next step will be connecting some Canbus warning cancellers between the ballast and my 12V connectors as an extra.

I also thought of another possible solution. There is a possibility that the peak voltage after starting the Xenon kit triggers the problem. So, by connecting the ballasts directly to my battery via a relay I will be effectively removing that peak voltage when turning the Xenon lights on right? This is just an idea....any thoughts on this?

Nine8Six 07-29-2014 03:38 AM

Quote:

Originally Posted by Edreamsz (Post 411995)
Hi guys, here's an update.

Yesterday I received a pair of ballast with a build-in Canbus solution (ballast/starter/Canbus in one box). I turned the Xenon kit on and immediately my oil warning lamp went on :mad:.

So, these units are going back. My next step will be connecting some Canbus warning cancellers between the ballast and my 12V connectors as an extra.

I also thought of another possible solution. There is a possibility that the peak voltage after starting the Xenon kit triggers the problem. So, by connecting the ballasts directly to my battery via a relay I will be effectively removing that peak voltage when turning the Xenon lights on right? This is just an idea....any thoughts on this?

?!?!?

Yes I know its not your kit. Bat's car problem made me realized this already. I was under the impression you were following our conversation :confused:

Check your voltage regulator "under load" it should read about 15.x volts (needs load tester, not a volt meter!). Your indy should be able to help with that. Those (brushes) gets tired with time, especially after 10+ years ;)

Others, as important: diode, alternator pulleys, loose serpentine strap, bad battery.

There are two phases to your ballasts' power up sequence:
- PhaseI: igniters (max load at 7amps for 1~2secs)
- PhaseII: stabilization (max load 3.5amp)

When phaseI occurs, it simply drains the car system's current. If the car charging system is not up to specs, you will "certainly" get unstable voltages (and of course, a nice shiny BATTERY MIL to tell you all about that!).

That's why the problem doesn't replicate when you switch on/off your lights i.e when phaseI is already hot and doesn't need as much current to ignite.

Fix the charging system and all should shine like a diamond again
^ Quote from my indy who've helped me out on this one, and who've seen a few pcars having the same issues as you are having now

Good luck

Edreamsz 07-29-2014 04:26 AM

Quote:

Originally Posted by Nine8Six (Post 411998)
?!?!?

Yes I know its not your kit. Bat's car problem made me realized this already. I was under the impression you were following our conversation :confused:

Check your voltage regulator "under load" it should read about 15.x volts (needs load tester, not a volt meter!). Your indy should be able to help with that. Those (brushes) gets tired with time, especially after 10+ years ;)

Others, as important: diode, alternator pulleys, loose serpentine strap, bad battery.

There are two phases to your ballasts' power up sequence:
- PhaseI: igniters (max load at 7amps for 1~2secs)
- PhaseII: stabilization (max load 3.5amp)

When phaseI occurs, it simply drains the car system's current. If the car charging system is not up to specs, you will "certainly" get unstable voltages (and of course, a nice shiny BATTERY MIL to tell you all about that!).

That's why the problem doesn't replicate when you switch on/off your lights i.e when phaseI is already hot and doesn't need as much current to ignite.

Fix the charging system and all should shine like a diamond again
^ Quote from my indy who've helped me out on this one, and who've seen a few pcars having the same issues as you are having now

Good luck

Yes, I was (of course!) following the thread but already ordered and received the other ballasts. My next stop is a load test to test my charging system. Will give an update this week!

Nine8Six 07-29-2014 04:44 AM

There is a 986 on the Chinese Porsche forum here with the exact same issues that Bat and yourself are having. MIL, batt/oil, spoiler tak tak tak thingny

He was running an aftermarket 2DIN deck with LCD, 400watts amp, GPS module, some depo LEDs tailights and a nice and expansive aftermarket iPhone charger - all at the same time! When he starts the car with accessories turned ON he gets these lights, if he turns accessories OFF and start the car, all is fine.

Luckily for him it was only a bad battery but none the less, his thread is about 7 pages long lol

Luck mate

Edreamsz 07-29-2014 04:48 AM

Hahaha, he is running a lot more than me at this time :). But let's hope it's an easy one!



Quote:

Originally Posted by Nine8Six (Post 412006)
There is a 986 on the Chinese Porsche forum here with the exact same issues that Bat and yourself are having. MIL, batt/oil, spoiler tak tak tak thingny

He was running an aftermarket 2DIN deck with LCD, 400watts amp, GPS module, some depo LEDs tailights and a nice and expansive aftermarket iPhone charger - all at the same time! When he starts the car with accessories turned ON he gets these lights, if he turns accessories OFF and start the car, all is fine.

Luckily for him it was only a bad battery but none the less, his thread is about 7 pages long lol

Luck mate


Nine8Six 08-01-2014 08:26 PM

Update
 
Hey all - Aug 1st. As mentioned in a previous post, those shinny lights are long gone :(

Some good news: Pelican Parts have kindly agreed to carry the "Performance Bi-Xenon Optics" projector kits in their online catalogue. So they will still be available for both the Boxster 986's and the 911's in the Autumn! It should make it easier for some of you guys to simply order them from Pelican. You'll spend less on shipping and get them five times faster than if you would order them from me. Huge thanks goes to Pelican for that!!!

I'll pass over the links as soon as I see them appearing in their catalogue for sure.

August will be a busy month here, but will sure keep updates coming as usual. In a meantime, here goes the last 3 kits I've made for some friends :)

http://986forum.com/forums/uploads01/011406952918.jpg

http://986forum.com/forums/uploads01/021406952931.jpg

http://986forum.com/forums/uploads01/031406952956.jpg

http://986forum.com/forums/uploads01/041406952969.jpg

^ this was by far the hardest kit to see leaving, the red one, Luminoso, white angel eyes (arrrggg). That is exactly what I am dying in putting into my car :mad:

Nine8Six 08-01-2014 08:30 PM

arrrggg x1000 lol

http://986forum.com/forums/uploads01...1406953829.jpg

BruceH 08-01-2014 09:26 PM

Quote:

Originally Posted by Nine8Six (Post 412713)
^ this was by far the hardest kit to see leaving, the red one, Luminoso, white angel eyes (arrrggg). That is exactly what I am dying in putting into my car :mad:

So what is stopping you? You need to just do it! Glad to see they will be available to a wide audience:cheers:

Pdwight 08-01-2014 09:28 PM

Me Too
 
The very same

Nine8Six 08-02-2014 03:36 PM

Quote:

Originally Posted by BruceH (Post 412716)
So what is stopping you? You need to just do it! Glad to see they will be available to a wide audience:cheers:

I was waiting for everyone's kits to be finalized so I can crack on a kit for myself Bruce, and that of course never happened. From the look of it, I'm looking at retrofitting my own car's headlights in Sept.

Promise an epic update, stay tuned ;)

BruceH 08-02-2014 04:08 PM

Quote:

Originally Posted by Nine8Six (Post 412796)
I was waiting for everyone's kits to be finalized so I can crack on a kit for myself Bruce, and that of course never happened. From the look of it, I'm looking at retrofitting my own car's headlights in Sept.

Promise an epic update, stay tuned ;)

Sounds good, sometimes you just have to take some time for yourself:cheers:

eicheldp 08-03-2014 03:32 PM

[QUOTE=Nine8Six;412713]Hey all - Aug 1st. As mentioned in a previous post, those shinny lights are long gone :(

Some good news: Pelican Parts have kindly agreed to carry the "Performance Bi-Xenon Optics" projector kits in their online catalogue. So they will still be available for both the Boxster 986's and the 911's in the Autumn! It should make it easier for some of you guys to simply order them from Pelican. You'll spend less on shipping and get them five times faster than if you would order them from me. Huge thanks goes to Pelican for that!!!

I'll pass over the links as soon as I see them appearing in their catalogue for sure.

August will be a busy month here, but will sure keep updates coming as usual. In a meantime, here goes the last 3 kits I've made for some friends :)


http://986forum.com/forums/uploads01/031406952956.jpg

Hi Fred,
Great news on picking up Pelican Parts as an outlet for your projectors! They are going to be a great success for you.
Are those Gun Metal Grey Vivo projectors on their way to a domicile in Pennsylvania? Can't wait :D

You need to take the time and build that red set for yourself and get them installed soon.

Nine8Six 08-03-2014 03:43 PM

Quote:

Originally Posted by eicheldp (Post 412900)
Are those Gun Metal Grey Vivo projectors on their way to a domicile in Pennsylvania? Can't wait :D

You need to take the time and build that red set for yourself and get them installed soon.

They are they are!!! Well spotted ;) As requested, leaving this Monday morning.

They are absolutely stunning... you'll also want them for your other cars, bikes, boats, whatever you need crisp and sharp lighting fitted onto lol

Hope you had a great holiday Don :) Mine is coming on the last week of Aug... off to an undisclosed top secret area for 1 full-short week, only. No mobile phones, PC, anything! Juss me and the wifey :cheers:

Coaster 08-04-2014 04:19 PM

I'm so sad I can't say I got these from you (still saving the fun money budget). Happy Pelican will have them.

Nine8Six 08-04-2014 09:29 PM

Quote:

Originally Posted by Coaster (Post 413079)
I'm so sad I can't say I got these from you (still saving the fun money budget). Happy Pelican will have them.

Ah you are still going to get them from me! In fact, the one who will machine, hand polish, anodize, laser etch and assemble them will be myself. (lol "by myself"... sounds like a famous scammer quote?!)

The way it will work is the (easy) machining bits will be outsourced to a friend's shop (e.g. adapter kit, cap, screw, shroud, composites) however, the bezel's precision machining, polishing, anodizing, laser, assembling stays in-house. That way I can continue to assure QC and needless to say save us all a ton of $ by being able to do this part ourselves. For info; precision machining on a thin-walled part made of highest grade aluminum, involving 2.5D, 3D, 4th multi axis both milling & lathe operations, it can quickly go up sky high in price :/ Some figures to put things in perspective: the bezel work alone (outsourced) cost $130 each (that is $260 for L&R, at "manufacturer price" with min qty requirements). It's brutal but the reality.

So that said, I am still going to have to work my cute little butt overtime to get those out on the market at a reasonable price. Lucky me I have a good buddy here who is helping me out but he is yet to be 'as passionate' as myself doing this kind of work (after hours, relaxing, bg metal cutting machine music, etc). Not his kind of thing (he like sofas) but perhaps when we'll start getting paid things may change, hoping for the best lol

RE Pelican Deal. Well, I have to admit I'll eternally be grateful to them. They are being kind here. Especially to me, but also to the crowd here and to other Porsche enthusiasts. Correct me if I am wrong but it wouldn't be the first time the team @ Pelican support a member's product. They have done it in the past and the message I got was they will continue to do so for any product/trick/tool/whatever they believe our little pcar community could benefit of. They are great people working there, ... definitely nothing to do with the other typical stone cold car part $hops!

Price-wise. Let's start by admitting that this clandestine operation had to stop (not a 'hobby' anymore lol). Some additional overhead will be required so the price may be slightly higher than previously advertised. I also have to get the product shipped out using legal means, using a registered trading co, paying my Chinese export taxes (cheap, 4% lol), and Pelican Co has to pay for storage, logistics, man I pass so many other things. The good news is these guys at Pelican have the ability to order few-more-than-one kit at a time so the prices gets so much more relaxed (thanks Pelican for that, not me. Their idea). So at the end, they are NOT going to be much more expansive than now, or whatever it will cost more it will be plenty justified, legal and fair I think :)

^ side comment... please do remember those kits shaves min 10 years off the look & feel of the Boxster/996s. Now that alone, to me, is priceless

As soon as the catalogue links turns up you bet I'll post them up bright red with flashy disco balls and all ;)

A true 986forum community effort, inspiring! Thanks x1,000,000

Davev 08-05-2014 05:15 AM

Very happy for you. Glad I could be part of the incubation process and love my v2.0 lights. They are the mod that people ask most about. But most important to me was the big increase in night time visibility. Fabulous product.

As soon as they make it to Pelican, I will add a review.

Davev 08-05-2014 07:46 AM

Here's looking at you:

http://986forum.com/forums/uploads01...1407253574.jpg

Coaster 08-06-2014 11:22 AM

AWESOME Nine8Six!

I'm day dreaming of a set of your projectors, switchback led lighting for DRL/turn signals, and integrating an auto-on switch/system. I know that may not be everyone's cup of tea but I smile when I see it in my head, lol.

MitchSF 08-08-2014 07:15 AM

How are you wiring your angel eyes? I want to use an ignition switched 12v source independent of the parking lights. If I have to, I'll run a wire from the fuse block.

Is it possible to order male and female pins to fit the existing connector, since there is space for more contacts? If so, can someone find the part numbers?

I plan on using one relay to control the high beam so that when the low beam is on and the high beam is flashed, the shutter will open. When the low beam is off, the halogen high beam will flash. I've done this before and it works well. Another set of contacts on the relay will shut off the angel eyes when the xenon light is on.

jaykay 08-11-2014 01:08 PM

Quote:

Originally Posted by Nine8Six (Post 404802)
The covers would need to go.

Coaster, Jaykay

I see both of you wants to retrofit Litronics. My advice on that subject is this. Many values the litronic as they are, factory, Porsche brand, DOT approved, whatever reasons. They are not bad lighting at all. If your plans are to go for full bi-xenon + CGT style front-end, the best would be to sell your Litronic to a member here and buy a NEW set of halogen to retrofit. You'll break even $-wise I'm sure, and someone will be pleased to have your Litronic I guarantee. Everybody's happy

If it would be me, that's what I would do anyway. Besides, no serious R&D nor design have been carried on Litronic headlights as yet :/

Sounds like a plan! Having never even removed my lights, would I be able to interchange them at will? I want to be able to plug my Lits back in with all the original functionality....and also power up the projectors with high, low fog capability.

We would really be able to test the difference!!

eicheldp 08-16-2014 03:44 AM

Quote:

Originally Posted by Nine8Six (Post 412902)
They are they are!!! Well spotted ;) As requested, leaving this Monday morning.

They are absolutely stunning... you'll also want them for your other cars, bikes, boats, whatever you need crisp and sharp lighting fitted onto lol

Hope you had a great holiday Don :) Mine is coming on the last week of Aug... off to an undisclosed top secret area for 1 full-short week, only. No mobile phones, PC, anything! Juss me and the wifey :cheers:

Hi Fred,

:D They're Here! :D

The projectors arrived yesterday and the are beautiful. Right now, they are sitting on my desk, waiting for November and a trip to the mid west for installation. Cheers :cheers:

Thanks again
Don


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