Porsche Headlight Retrofit [from CAD, prototyping to finish)

[reiver]

Originally Posted by Nine8Six

Next step, in the oven at 200degree for 72hrs nonstop. Hope those parts and etching, edges, etc will pass the test.

If it comes out well, would you make a pair for sell?

/another red boxster that needs some new headlights...

[Nine8Six]

Originally Posted by reiver

If it comes out well, would you make a pair for sell?

/another red boxster that needs some new headlights...

I'm building this GT headlight based on one specific bi-xenon assembly. Meaning you'll need the same kit: 2x GT style shrouds + 2x bi-xenon projectors. Still cheap no worries there. Not super high tech as you can see.

Any retailed HID lighting can be used to fire up the kit I'm guessing.

Let's talk when completed. I may send this design to a manufacturer if a few of the 986 and 996 guys are interested. For now let's hope all turn up to be what it should Wish me luck.

[reiver]

Originally Posted by Nine8Six

I'm building this GT headlight based on one specific bi-xenon assembly. Meaning you'll need the same kit: 2x GT style shrouds + 2x bi-xenon projectors. Still cheap no worries there. Not super high tech as you can see.

Any retailed HID lighting can be used to fire up the kit I'm guessing.

Let's talk when completed. I may send this design to a manufacturer if a few of the 986 and 996 guys are interested. For now let's hope all turn up to be what it should Wish me luck.

Can't wait to see the final product!

[Leebherron]

Finished, looks quite hot (red) !
Thanks Fred

[Van914]

I would be interested in a pair if you develop for sale.
Great project!
Van

[Nine8Six]

Teaser for the moment. This is where I'm going with that project.

Already looking good from the picture so in theory, it should looks even better in real life Everything is cooking for another 2 days so I'll take the weekend off on this one. I'll get back to work this coming Monday or Tuesday evening. Hopefully I should have received the headlights by then.


(Picture credit goes to member Boxster7614. His built with the black interior was my main source of inspiration).
See his thread at: Black HIDs

[Nine8Six]

Originally Posted by Van914

I would be interested in a pair if you develop for sale.
Great project!
Van

2-4weeks max project. I'll keep updates coming

Thanks Van

[Reebuck1]

Nine8six, I am also interested if you make a set. Thanks

[nakedteets]

Interested in a set if you sell one

Sent from my SAMSUNG-SGH-I747 using Tapatalk 2

[Nine8Six]

Originally Posted by nakedteets

Interested in a set if you sell one

Thanks for the support, nice one!

Ok, I'll run a batch on those and list them on my ebay for grab. Of course I'll keep you Reiver, Takart and Van on priority no worries.

[TAKART]

Originally Posted by Nine8Six

Thanks for the support, nice one!

Ok, I'll run a batch on those and list them on my ebay for grab. Of course I'll keep you Reiver, Takart and Van on priority no worries.

THANK you. I did like you and order the headlights same with the white corner. please keep us updated. did you get my pm?

[986_inquiry]

looks good

i've been looking for a way to convert my 987 foglights to good LED like modern porsches have.

Cayman LED Spars with Radiator Guards (fits 2006-2008) Group Buy - was making some for the cayman and offered to make some for the boxster but there wasn't enough interest

[dbansal]

It always amazes me how motivated some people are! Awesome!

[TAKART]

the only pattern we see is this some other will simply be stalking (sick). I think you need some serious help woodsman

[AKnowles]

For my two cents worth, all I can say is very impresive indeed.

[particlewave]

Seriously nice work!

[Nine8Six]

Finally done selecting the paint after completing a non-stop 67hrs cooking session at 225degree on two different unit. Without a peel or a single bubble. I'm pretty convinced the unit will be able to endure a few years of medium to hot weather.

*Design update*

I've designed a custom lens mounting system to achieve a simpler assembly. Therefore no more fitting PVC cylinder and gluing shroud ideas! What I got now is a solid and lightweight aluminum complete unit. Installation should be as easy as replacing a light bulb.

Other than that not much more. I've shorten the shroud by 10mm making it look a bit more like the Carrera GT lens. It's now 30mm in length. Looks far better imo


See through view. I haven't bothered to model the cutoff plate and the solenoid. They do not interfere with the design so pointless to waste time there.


Sliced view of the assembly. The weird box inside is are only proportions and represents the compartment for the solenoid ie. the coil that activate the cutoff plate (high/low beams flip flap thingny).


How the unit will be assembled. The four tabs of the skirt will be secured with SS304 M4 screws, shroud and lens mounted with 1,300 degree high temp industrial epoxy (very expansive stuff, and unforgiving).


The back view. I've left two ventilation ducts. Unfortunately I am being told by the manufacturer of the projector that the unit can't be closed completely. This is to ensure the longevity of the HID bulb.


Rendering of the assembly. This is the whole unit really. Clean and Plug-&-Play!


Will update as it goes. Moving on to shopping for materials tomorrow, CAM work thursday and production on Friday eve and (very possibly) the weekend as well. We'll see how things pans out here.

[Nine8Six]

Originally Posted by 986_inquiry

looks good

i've been looking for a way to convert my 987 foglights to good LED like modern porsches have.

The guy to ask here is Particlewave. Having seen a few of his threads and DIY, he clearly knows more than anyone in the trade RE this kind of stuff.

Originally Posted by dbansal

It always amazes me how motivated some people are! Awesome!

Passion for whatever you do is key. Motivation, call it the way you want. Thanks!

Originally Posted by TAKART

THANK you. I did like you and order the headlights same with the white corner. please keep us updated. did you get my pm?

You go too fast for me Takart but I appreciate the support. Cheers mate. PM replied (ouch).

Originally Posted by The French Dude

Hmmmm I just saw this interesting topic !
I would like to see the result in real life if it's not a problem.

Don't see any problems, of course.

Originally Posted by AKnowles

For my two cents worth, all I can say is very impresive indeed.

Mostly fun and relaxing project mate. The real impressive stuff is locked away on an encrypted hdd

Thanks for looking guys. great encouragement, great forum, brilliant people!

[kjc2050]

Looking forward to seeing the finished product!!!

[Van914]

These look great!
Congrats on your work.
Van