Porsche Headlight Retrofit [from CAD, prototyping to finish)

[rfuerst911sc]

I haven't installed mine yet as I'm waiting for the new seals to be built but my lights are already old news I guess you can't stop progress

[BFeller]

Originally Posted by particlewave

I hope to have them installed in 2-3 weeks and will post results

I also plan to finally do a full write up with pictures and videos of the retrofit process for the die-hard DIYers like myself

It's not rocket science, but there are many opportunities to damage things.

I purchased a used set of headlights. I opened the backs of the lights because they were rattling and found that each light had an HID kit installed. The rattling came from ballasts which were lose inside cover that seals the access to the bulbs. It looked like the weight of the ballasts had knocked the light buckets off the pivot ball. Also the seal on one light was mush. Thursday was spent polishing the yellowed and gunk-ed up lenses. They now are looking like brand new.

Today I used Particlewave's video to open both headlights. I baked the first one for 15 minutes with no give on the silicone. It went back into the oven for another 10 minutes since it had cooled a bit. It came apart easy enough the after the second bake. The second one went in for 20 minutes and came apart quickly. It was then easy to pop both of the headlight bucket assemblies back onto their pivot balls. The internal lens covers came off with only one plastic tab having broken. Once the internal light covers were off there was dust or dirt around the reflectors. It looked like residue from a bulb burning off moisture.

Next step have to be ordering the new projector lights.

[particlewave]

Originally Posted by BFeller

I purchased a used set of headlights. I opened the backs of the lights because they were rattling and found that each light had an HID kit installed. The rattling came from ballasts which were lose inside cover that seals the access to the bulbs. It looked like the weight of the ballasts had knocked the light buckets off the pivot ball. Also the seal on one light was mush. Thursday was spent polishing the yellowed and gunk-ed up lenses. They now are looking like brand new.

Today I used Particlewave's video to open both headlights. I baked the first one for 15 minutes with no give on the silicone. It went back into the oven for another 10 minutes since it had cooled a bit. It came apart easy enough the after the second bake. The second one went in for 20 minutes and came apart quickly. It was then easy to pop both of the headlight bucket assemblies back onto their pivot balls. The internal lens covers came off with only one plastic tab having broken. Once the internal light covers were off there was dust or dirt around the reflectors. It looked like residue from a bulb burning off moisture.

Next step have to be ordering the new projector lights.

Excellent work!
Those ball joints cause me more headache...

[tightbox]

Make sure to spray a permanent protective UV coating on the newly polished lenses, or they will be cloudy again in no time!

[particlewave]

Originally Posted by tightbox

Make sure to spray a permanent protective UV coating on the newly polished lenses, or they will be cloudy again in no time!

Absolutely! Followed by a light polish, they will shine like new!

Now, if only something could be done about the darn internal crazing of the lens...

[tonichristi]

I've read this thread many times and really love the look of these latest projectors. I like the one above with the angled edge.

I think this modification is a little out of my league

[tightbox]

Particle - what UV spray do you use? I purchased some clears that were a bit rougher than represented in the sales description, so I'm still in the research phase currently.

[particlewave]

To be honest, I'm pretty new to the whole restoration thing. I only did a couple of sets for members here because they were so bad that I couldn't make them any worse.

That said, Optimum Opti-lens is some pretty awesome stuff, but not a spray and pricey.
What have you tried?

[tightbox]

Haven't tried it yet, just received some lenses that were in worse shape than I would have liked, and have been researching what to do (other than mail them back to the seller!).

Wonder if I could use a regular UV stable automotive clear coat from paint scratch.com?

[Nine8Six]

Originally Posted by tightbox

Haven't tried it yet, just received some lenses that were in worse shape than I would have liked, and have been researching what to do (other than mail them back to the seller!).

Wonder if I could use a regular UV stable automotive clear coat from paint scratch.com?

Mine were original lenses and they received no special care for ten+ years and had some minor scratches so they had to be wet sanded at some stage. Although NOT recommended by any pro it worked for me. I didn't used UV protect whatsoever BUT I have to regularly polish them when I do the 986's quarterly detailing. Edit: takes 10min per headlight

I'm just saying this because the lenses looks as new as the day I restored them 36+ months ago. Guessing if you maintain them regularly it shouldn't be any different for yours.

Been using Meguiar's Plast-X Clear Plastic Cleaner. Could well have UV protect additives dunno... rarely read labels These polish products are all the same thing really (de-oxidizers + ultrafine abrasive particles)

[BFeller]

I think the Turtle Wax or Mequire's headlight kit comes with a UV protectant for the plastic. A wipe on treatment that seems to be one that gets repeated like waxing.

[particlewave]

FYI - For readers interested in the retrofit, I am booked full through August 15.

Kits are still available for DIYers

[MitchSF]

Another option is to use Lamin-X. The thick, clear headlight film does a good job of hiding small scratches.

[Crono0001]

Particlewave

Am I included in the "before August 15th" group?
My projectors should be reaching you Monday!!

[particlewave]

Originally Posted by Crono0001

Particlewave

Am I included in the "before August 15th" group?
My projectors should be reaching you Monday!!

Absolutely! Got you penciled in

[Nine8Six]

Originally Posted by particlewave

FYI - For readers interested in the retrofit, I am booked full through August 15.

Kits are still available for DIYers

They are available yes but I am one week late in getting them out now. Trying my best to catch up with time but with 18 orders/kits on the backburner atm, its pretty damn hard to meet up my 1(one) week mfg-time promise :/

Kits shipping this coming Tuesday for Fergus, Simon and Ed. Next batch sends out this coming weekend.

Your customer's kits are being mfg this coming week Charles, shipping beg of next week.

[BruceH]

Finally got mine installed thanks to the outstanding work of Charles and Fred! I have to say that both of these guys are fantastic guys to work with. We had some UPS issues which caused quite a bit of damage but Charles was able to repair everything to better than new, thanks again for all of your hard work and contributions to this forum!

[Nine8Six]

Originally Posted by BruceH

Finally got mine installed thanks to the outstanding work of Charles and Fred! I have to say that both of these guys are fantastic guys to work with. We had some UPS issues which caused quite a bit of damage but Charles was able to repair everything to better than new, thanks again for all of your hard work and contributions to this forum!

Oh cool Bruce!!! Looking good.

and what's that blue reflect on the above pic? A Charles' special devil eye effect, LED, how did you guys managed that?

[BruceH]

Originally Posted by Nine8Six

Oh cool Bruce!!! Looking good.

and what's that blue reflect on the above pic? A Charles' special devil eye effect, LED, how did you guys managed that?

That's just the lights on, I was surprised it looked blue as well. Bonus I need to adjust the height of the beams, they are a bit low. High beams sure light the place up!

[particlewave]

Originally Posted by rfuerst911sc

Another mini update on the replacement seals . Just received an email from the supplier the tooling will be 5k but he feels like the numbers of 986/996 out there that may need these seals is great enough to move forward with the project. He has ordered the material to make the dies he estimates we are 8 weeks away from having a first piece article !!! He is going to make one side first I can't remember if I sent him a driver or passenger side ? If the fit is good he'll then do the opposite side. I may have to send him my old seals to get the other side but that's not a problem. Who knows with a little luck maybe these will be available by year end or a little sooner !

That's good news! I have 2 sets of my own with gummy seals.

Originally Posted by BruceH

That's just the lights on, I was surprised it looked blue as well. Bonus I need to adjust the height of the beams, they are a bit low. High beams sure light the place up!

You have the adjustment instructions, right? I try to get them close, but there are always differences in cars due to ride height, etc.
If you need any help, let me know. Just be sure to keep an eye on the projectors when adjusting