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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)

PaulE 08-12-2016 04:19 PM

I've ordered a kit and am going to take the plunge, but I have a few questions, some of which will be answered when the kit arrives. Looking at some of the pictures of finished conversions, it seems like some have chosen not to paint their reflector bowls or any other interior parts. Is that correct? I think I would prefer not to do any painting, but if everyone else has painted and that's the way it really looks good, I guess I will paint.

Reading the instructions, it looks like the hole for the high beam bulb just stays empty? Do I need to remove the ring that holds the high beam bulb in?

Looking at the instructions and the picture of the kit, there are wires from the projector bulb and angel eyes that go to the connectors for the old bulbs. Do those wires come with the kit, or do I need to buy those separately? If I need to buy wire, what size?

http://986forum.com/forums/uploads02...1471047472.jpg

Are the extra wires on the diagram in the kit although they're not shown in the kit picture?

http://986forum.com/forums/uploads02...1471047515.jpg

Nine8Six 08-12-2016 06:19 PM

Hey Paul

1. You must paint the interior with satin black otherwise the car just won't start. Seriously; its your choice really. All of today's (modern) sport cars have them with black interiors hence the idea of painting them. That's what look best (x1,000) if you ask me, but not mandatory at all.

2. The high beam becomes obsolete with those bi-xenon optics, and so is the socket/hole for the bulb. It is safe to remove the bulb... the back sealed cover is sufficient to prevent dusts to enter the headlight assembly. The high beam connector's 12v is what triggers the bi-xenon solenoid cutoff plate!

3. You do not have to buy additional wires. Those are all included in the kit. They just don't show up on the rendering you've posted above (got lazy doing CAD cabling loll).


Shipping all 26 kits along with a few center caps this coming week!! Crazy I know (twenty-six kits).

Busy this weekend re-machining the small adapters that house the HID bulb in the back of the projector :/ I guess that's what happen when you get new machine-tools and German controllers. Those were initially threaded with a 1.25mm thread while the optic takes a 1mm thread. Crazy mistake... luckily those are quite easy to remake but regardless I have to throw out 180+ parts in the bin.

Nine8Six 08-12-2016 06:52 PM

^ Re-doing those little adapters on the benchtop lathe this time. One-by-one, just got 52 to do lolll Not the fastest (time: 2m40s/adapter) but at least I know that this controller will behave and thread those as per postprocessor. I'll sort out the production lathe's controller/threading cycle next week.

Life: How to screw up your Saturday night!

http://986forum.com/forums/uploads02...1471056532.jpg

BruceH 08-12-2016 09:44 PM

Mine are not painted and love the way they turned out. Really a personal preference. Take a look through the thread to see what you like best :cheers:

heliguy 08-13-2016 03:36 AM

That is a beautiful website, Fred.

PaulE 08-13-2016 02:43 PM

Thanks!
 
Quote:

Originally Posted by Nine8Six (Post 506451)
Hey Paul

1. You must paint the interior with satin black otherwise the car just won't start. Seriously; its your choice really. All of today's (modern) sport cars have them with black interiors hence the idea of painting them. That's what look best (x1,000) if you ask me, but not mandatory at all.

2. The high beam becomes obsolete with those bi-xenon optics, and so is the socket/hole for the bulb. It is safe to remove the bulb... the back sealed cover is sufficient to prevent dusts to enter the headlight assembly. The high beam connector's 12v is what triggers the bi-xenon solenoid cutoff plate!

3. You do not have to buy additional wires. Those are all included in the kit. They just don't show up on the rendering you've posted above (got lazy doing CAD cabling loll).


Shipping all 26 kits along with a few center caps this coming week!! Crazy I know (twenty-six kits).

Busy this weekend re-machining the small adapters that house the HID bulb in the back of the projector :/ I guess that's what happen when you get new machine-tools and German controllers. Those were initially threaded with a 1.25mm thread while the optic takes a 1mm thread. Crazy mistake... luckily those are quite easy to remake but regardless I have to throw out 180+ parts in the bin.

Thanks for the info Fred, this is going to be a winter project for me. It will give me some time to think about the paint!

particlewave 08-25-2016 09:20 AM

...................

F18febe 08-27-2016 05:04 AM

Blinking angel eye
 
https://youtu.be/TMVHdNleMHI

I've had the projectors installed for about 8 months now and one of the
Angel eyes is now blinking. I rewired everything on the
Back of the headlight and it is still blinking. Take a look at the video.
Any ideas? I really don't want to crack the lens open again.

georgewd3 08-27-2016 06:30 AM

I've been having some problems with these headlights firing up for a few months now. The problem is this, I start the car and then turn on the headlights. Sometimes they fire right up and gradually brighten but sometimes they don't fire up at all. Last night they fired up, warmed up and I started driving. I was on a back road and hit the high beams. The headlights turned off. Turning the headlight switch on and off didn't do anything. Pulling the high beam switch made a momentary flash but didn't turn the headlights on. I pulled to the side of the road and after fiddling with the switches including the high beam, the lights fired up and then worked perfectly for the drive home.

Any thoughts on what to look for?

particlewave 08-27-2016 08:03 AM

Quote:

Originally Posted by georgewd3 (Post 508030)
I've been having some problems with these headlights firing up for a few months now. The problem is this, I start the car and then turn on the headlights. Sometimes they fire right up and gradually brighten but sometimes they don't fire up at all. Last night they fired up, warmed up and I started driving. I was on a back road and hit the high beams. The headlights turned off. Turning the headlight switch on and off didn't do anything. Pulling the high beam switch made a momentary flash but didn't turn the headlights on. I pulled to the side of the road and after fiddling with the switches including the high beam, the lights fired up and then worked perfectly for the drive home.

Any thoughts on what to look for?

Pull the headlight switch and give it a good cleaning by spraying contact cleaner inside of it while switching it back and forth.

particlewave 08-27-2016 08:07 AM

Quote:

Originally Posted by F18febe (Post 508021)
https://youtu.be/TMVHdNleMHI

I've had the projectors installed for about 8 months now and one of the
Angel eyes is now blinking. I rewired everything on the
Back of the headlight and it is still blinking. Take a look at the video.
Any ideas? I really don't want to crack the lens open again.

Looks like it's failing. Unhook it for now (both) and I'll put together some tests for you to find out for sure.

F18febe 08-27-2016 09:58 AM

Thanks a bunch, PW.

particlewave 08-27-2016 10:29 AM

FYI for all that have these installed or plan to install
 
LEDs don't like heat. The LED angel eye halos are inside of the projector unit with the HID bulb, so you really don't want them powered on while the HIDs are on.

It is wise to put them on a relay so that they are off when the HIDs are on. This will greatly extend their life and prevent premature failure. Wiring shown below...

http://986forum.com/forums/uploads02...1472322587.jpg

rfuerst911sc 08-27-2016 02:18 PM

Today I finally installed the headlights I purchased 2 years ago ! How time flies when you are busy . Anyway I picked up some seals locally and treated them with a good coating of Vinylex before installing . Installed the seals and started the remove/replace sequence. It was surprisingly easy and no drama to report . I started the car, started going through the various light checks and the damn things worked :D I did have a slight rattle in one light but after looking the light over one of the sockets had come unseated. Gently pulled/prodded until I felt it pop into place. I went with no angel eyes and kept the amber interior lense but went with grey/smoke outer lense. I think it looks great .
If these pics work out they are some crappy pics I took inside the man cave today.

http://986forum.com/forums/uploads02...1472336306.jpg

rfuerst911sc 08-27-2016 02:20 PM

Ummm hit the send button too soon :D


http://986forum.com/forums/uploads02...1472336395.jpg
http://986forum.com/forums/uploads02...1472336427.jpg

PaulE 08-29-2016 07:47 AM

Can you tell us what relay?
 
I'm waiting for my kit and the relay looks like a good idea. Can you tell us what relay to use? Also, the wiring diagram pictures show the interior/back of the headlight with the stock bulbs in place. Does anyone have any pictures of the wiring with the actual projector lights in place and showing where/how to mount the relay? Thanks!

Quote:

Originally Posted by particlewave (Post 508055)
LEDs don't like heat. The LED angel eye halos are inside of the projector unit with the HID bulb, so you really don't want them powered on while the HIDs are on.

It is wise to put them on a relay so that they are off when the HIDs are on. This will greatly extend their life and prevent premature failure. Wiring shown below...

http://986forum.com/forums/uploads02...1472322587.jpg


PaulE 08-29-2016 07:50 AM

rfuerst911sc thanks for those pictures. I am not going to paint the interior of my lights at all. Your pictures are very helpful to me, my 2003 seal grey headlights will look a lot like that, but I will have the angel eyes and no amber on the bottom!

Nine9ex 08-31-2016 06:48 PM

hey bro! What's the status on the delivery?

PaulE 09-02-2016 12:55 PM

Got an email last night from the GT Collection telling me my order has shipped! Woo Hoo!!!!

2000986s 09-16-2016 09:53 AM

Has anybody received their kit yet? I think I got the shipping confirmation a couple weeks ago but still no sign of em.

Nine8Six 09-16-2016 09:41 PM

Quote:

Originally Posted by 2000986s (Post 510374)
Has anybody received their kit yet? I think I got the shipping confirmation a couple weeks ago but still no sign of em.

Yours is the only one left that needs to register in the local post :/ I can confirm its out and in the Vivo series as per your exchange request! If lost (stolen?) I have many more here that I can express mail to you so don't worry about this.

I realize that timing is completely wrong however and I apologize for this.

Some less fumy invalid reasons; we got hit hard during the G20 event where security levels were at it's "never" experienced before. E.g. air-mailing anything above 1kg took min 5 days, some more, for the parcel to register in their system. International or local.... outbound electronics were automatically being inspected, if what I have been told 38 times (parcels) is true.

We also got any sort of tunneling and VPN access temporarily chopped off. There was no way to get data in/out of here for a full 12 days. Good news is my lovely wife got us a dial-in enabled SAT phone that works with a SIM card; monthly or as 'per use' billing plans so we won't have to blackout from modern societies again. Had everything Google Cloud blocked, server, vpn, email, all.

Glad I can read 986forum.com again also. The forum blocks IP from China, in case you guys didn't know. Google's srv, Cisco Webex, forums, gets bad sometimes lolllll

rfuerst911sc 09-17-2016 03:10 AM

I have never owned a vehicle with this type of headlight. It takes a little bit to get used to the very distinct cut off line of the projected light but they are very bright and I am quite happy with the setup. I may have to adjust the drivers side a little higher ( not much ) as the top of the projected cut off is a tad lower than I like. Passenger side is perfect and high beams are set to stun !!! :D

2000986s 09-17-2016 06:51 AM

Thanks a lot for the update, I really appreciate it. No worries on the timing, all I needed was an update! As long as I can get them on the car before she goes away for the winter, I will be happy:D

You did mention they might be lost/stolen? How much longer should we wait before considering them as such?

Feel free to PM me if easier otherwise I check this thread daily anyways.

Thanks again!!!

PaulDash 09-18-2016 03:46 PM

Removed the headlight covers today. Easy. All that was needed was an exacto knife. No oven.

Looking to paint interior black and install projectors.

http://986forum.com/forums/uploads02...1474242345.jpg

Smallblock454 09-18-2016 07:52 PM

Quote:

Originally Posted by PaulDash (Post 510596)
Removed the headlight covers today. Easy. All that was needed was an exacto knife. No oven.

Looking to paint interior black and install projectors.

http://986forum.com/forums/uploads02...1474242345.jpg

:D

Maybe your red paint has too much orange peel. Think your car paint needs to be polished first. ;) :D

Regards, Markus

BFeller 09-20-2016 09:01 AM

Quote:

Originally Posted by PaulDash (Post 510596)
Removed the headlight covers today. Easy. All that was needed was an exacto knife. No oven.

Looking to paint interior black and install projectors.

http://986forum.com/forums/uploads02...1474242345.jpg

What 'model' car is that one?

PaulE 09-21-2016 04:17 PM

I got a little package in the mail today, thanks Nine8Six! I almost got my money's worth in bubble wrap alone, everything arrived in perfect order!

http://986forum.com/forums/uploads02...1474503368.jpg

http://986forum.com/forums/uploads02...1474503407.jpg

RedBeauty 10-08-2016 04:06 AM

Has anyone else got their projectors? It's over 3 weeks since the tracking said it was shiped from china. Have'nt heard, seen anything since then. Lost / stolen?

2000986s 10-08-2016 06:07 AM

Mine shipped 5 weeks ago but the tracking number has never worked for me. I'm assuming lost/stolen.

Fred: will you be shipping a new kit or processing a refund until you can have some available?

BFeller 10-09-2016 10:21 AM

Quote:

Originally Posted by 2000986s (Post 512415)
Mine shipped 5 weeks ago but the tracking number has never worked for me. I'm assuming lost/stolen.

Fred: will you be shipping a new kit or processing a refund until you can have some available?

This is how things worked out for the various packages I've received from Fred:

The Shipping numbers start working once the packages are received into the US Postal System. This is after they trickle in from Orient. Fred's Foreign Post Office only releases a few packages a week.

My experience was that once the numbers starts providing information - my shipment is sitting on the door step.

PaulE 10-09-2016 11:31 PM

My tracking number never worked. Although the email said the tracking number was US mail, I think it was really China Post. Anyway they really did come to my house. I can't read the shipping label now because I'm out of town for another week.

JayG 10-10-2016 07:51 AM

Quote:

Originally Posted by Nine8Six (Post 510446)
Yours is the only one left that needs to register in the local post :/ I can confirm its out and in the Vivo series as per your exchange request! If lost (stolen?) I have many more here that I can express mail to you so don't worry about this.

I realize that timing is completely wrong however and I apologize for this.

Some less fumy invalid reasons; we got hit hard during the G20 event where security levels were at it's "never" experienced before. E.g. air-mailing anything above 1kg took min 5 days, some more, for the parcel to register in their system. International or local.... outbound electronics were automatically being inspected, if what I have been told 38 times (parcels) is true.

We also got any sort of tunneling and VPN access temporarily chopped off. There was no way to get data in/out of here for a full 12 days. Good news is my lovely wife got us a dial-in enabled SAT phone that works with a SIM card; monthly or as 'per use' billing plans so we won't have to blackout from modern societies again. Had everything Google Cloud blocked, server, vpn, email, all.

Glad I can read 986forum.com again also. The forum blocks IP from China, in case you guys didn't know. Google's srv, Cisco Webex, forums, gets bad sometimes lolllll

The joys of living in a Communist country!

RedBeauty 10-13-2016 08:37 PM

This is starting to get alitlebit frustraiting now. I understand that most of u guys have got yours. So since mine is registered i suspect lost / stolen in the post. I have tried to reach out to Fred, via PM here and by mail.. no answer at all

particlewave 10-13-2016 08:49 PM

Take a deep breath and calm down :)

These things take time. It's not unusual to take 6-10 weeks. The way it works is that he drops them all off at the post, then they only ship one or two per day (or week...can't remember). The reason is that he would get charged as a merchant, otherwise. That increases shipping cost, tax and they would be prone to inspections (laser scripting would not fly).

I've ordered dozens of sets of these projectors from Fred, so I know as well as anybody how painful the wait can be...sometimes they fly through, others take a couple months. They'll show up, I promise. Worst case scenario is that they are missing. If that's the case, I guarantee Fred will make it right. ;)

RedBeauty 10-13-2016 10:05 PM

Quote:

Originally Posted by particlewave (Post 513032)
Take a deep breath and calm down :)

These things take time. It's not unusual to take 6-10 weeks. The way it works is that he drops them all off at the post, then they only ship one or two per day (or week...can't remember). The reason is that he would get charged as a merchant, otherwise. That increases shipping cost, tax and they would be prone to inspections (laser scripting would not fly).

I've ordered dozens of sets of these projectors from Fred, so I know as well as anybody how painful the wait can be...sometimes they fly through, others take a couple months. They'll show up, I promise. Worst case scenario is that they are missing. If that's the case, I guarantee Fred will make it right. ;)

Good to hear. I can take the wait, as long as i know what's happening. I have full trust to fred, but i did'nt expect that the shipping would take this long. And it would be a shame if these expensive but realy nice projectors were lost :)

geetee 10-19-2016 08:11 PM

how much does it usually cost to have someone fit these into my headlights?

particlewave 10-19-2016 08:43 PM

Quote:

Originally Posted by geetee (Post 513707)
how much does it usually cost to have someone fit these into my headlights?

When I checked with theretrofitsource.com a few years ago, they were charging between $700-$1000. :eek:

I charged members here $250 for the basic retrofit + shipping cost. Paint was $50 extra for black, $75 for custom color (like matching the body color).
Not sure about others.

Meir 10-20-2016 07:51 AM

Quote:

Originally Posted by particlewave (Post 513708)
When I checked with theretrofitsource.com a few years ago, they were charging between $700-$1000. :eek:

I charged members here $250 for the basic retrofit + shipping cost. Paint was $50 extra for black, $75 for custom color (like matching the body color).
Not sure about others.

that is very reasonable in my opinion.

Van914 10-20-2016 07:02 PM

Particlewave does a great job. He converted mine and did some repairs.
Great job, communication and well worth the money.
Much easier than DIY
Thanks Charles

Van

tommy583 10-21-2016 02:56 AM

Charles is the man. If he is offering his services to do the retrofits DO NOT hesitate taking him up on the offer. He is the absolute expert on this procedure.


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