Porsche Headlight Retrofit [from CAD, prototyping to finish)

[Nine8Six]

Originally Posted by MitchSF

Did you remove the reflector bowl to paint it? I don't see how to remove it, and I don't want to break anything trying. Guess it can be painted in place, but I'd rather remove it if it's not too much trouble.

I will use VHT high temperature ceramic flat black paint for this.

I didn't. And I was happy to paint on the unit just in front of the bowl. When reassembled you have a 3/4" gap between the bowl and the headlight's insert and that also needs painting. Just lift the bowl to its highest position using the headlight adjustment HEX screw (lower one) so that the spray can reached under the bowl. That did the trick for mine.

If you really need to remove it, the assembly main mount screw is located behind the PIN connector. The connector has to be removed first (two screws, top/bottom). That's as far as I can help, I didn't removed mine so I don't know how much more effort there is after that main assembly screw. Careful, the assembly seems to be mounted on a snap/ball joint system. If your headlight is aged you don't want to pry anything there. PE material stiffen with age... better to just let it be (100% safer).

Flat black is by far tha best choice for a sport looking headlight, I couldn't agree more. But you will have to remind yourself to never park the front-end in direct sunlight. Not sure of the exact heat tolerance of the Porsche headlight but I know that matte black and sunlight are not good friends. I'd say if the car is garaged and occasionally driven, then Go-Go flat black. If not (e.g. DD) Satin Black is the safest.

I couldn't find any flat black in high temp here (for some reason). Satin finish only, which is closer to matte than gloss. I was quite surprised with the result but of course not 100% satisfied

[particlewave]

Originally Posted by Nine8Six

Anytime mate. There is a US based member who is looking at retrofitting his but doesn't have time to carry the job and want to send me his headlights. Can I send a kit to you (gift included) and he sends you his headlight for a retrofit job by you? Not far from you. He is happy to support financially I believe - send me a quote if interested.

I think we can work something out

I'll send you a pm after I get off work.

[Nine9ex]

Originally Posted by particlewave

I think we can work something out

I'll send you a pm after I get off work.

Just ordered the liumi's in g-metal!!! So excited! You and nine8six are a real inspiration!!!

Can I publicly beg for your help in finishing the deal and putting these together for my lovely, silver p-car?

Cheers mate!!

Matt

[Nine8Six]

Thanks Matt, received! Nice choice of angel eyes with those GM bud Let's hope Charles is not all too busy lately.

Note to all who got a kit recently; thanks for the overload :/ Wasn't expecting that many orders but I'm guessing with all the delays that I've inflicted, that's the price to pay. Been dedicated for the last full 5 days doing those for you guys.

If only I'd be getting rich at doing those lollllll (I think after the carbide cutters, 380V machine-tool electricity, dyes, other hardware, and prep, shipping, I think I make a rude & healthy 70$ profit on one kit). So... selling many is the idea! Sold 16 kits to you guys (incl Matt's) since the site is up. Oh, I've checked again and I have parts for 140 more kits left here so please ORDER your kit now - just kill those 90's halogen

LASER SCRIPT:

All of those 16 kits will be etch with PORSCHE PERFORMANCE OPTICS on the bezel (w/ series name at the bottom). Rewind a few million posts in this thread if you want to see what it looks like. If you need anything else please get in touch - those goes under the laser this coming Tuesday morning and pack right after (final step!).

[Nine8Six]

Small detail.

Read from the pro at HiDplanet : The Official Automotive Lighting Forum that some paints react to the chrome material used on some reflectors. So don't take the chance and sand the chrome finish off your bowls before applying your paint. Literally take 5 min per headlight with a #600 grit abrasive paper. The chrome is so burnt out by the halogen' heat that it comes right off - was a good sign that this had to go before painting

[MitchSF]

Thanks for the advice. I will paint the reflectors in place, and I will sand them first.

[TAKART]

also can you send me installation picture or save it on this post so we can see how to install the projector many people asking to see this. thank you fred

[ohhh my]

Can we get some cut off line pictures?

[Nine8Six]

Great.... I just washed the Boxster this afternoon and covered it back in the garage until its next pcar go out day. Will make a "video" of the next drive out so you can see that halogen is now officially phased out, and that HID rules!

Cutoff line is pretty standard for all bi-xenon projectors mate. You want to Google Image: "Morimoto Mini H1 cutoff line" for examples.

Pattern is identical to the one on the pic below:


The only advantages of my 'custom' projector against the stock Morimoto Mini H1 is the lens on mine are placed dead centered with the projector's bowl and its beam of light (factory quality). I machine those parts with 0.05mm precision/tolerance. The original projector comes with a cheap plastic lens housing with (often) uneven tabs all around (see pic below), or bent, and that can shift the lens a bit too much on some units. I've measured a few units and couldn't find a pair that had the same focal/lens alignment. Some are okay, some we're off by as much as 1.5mm. This can make the focal and horizontal cutoff line adjustment a PITA or even impossible.


^hmmmmm .... no thanks!

The mounting spacers and the socket nut/threads I provide are also machined to same high precision believe it or not. It makes everything pretty easy to line-up for the end installer

[Nine8Six]

A member PM'ed me (actually, blasted me) regarding my above reply to member Ohh my. The cutoff line question was more toward 'quality' reason and my reply was perhaps less than acceptable (fair enough). He also reminded me that I didn't specifically needed the 986 to prove that the cutoff line of my custom projector is standing up as much as the design/concept.

Well there you go. I've assembled a kit fired it up using a rectifier so I can shoot a few pics. Please don't comment on my photography skills.... that is something I need practice a lot on :/

Note that all projectors that I make are tested in a same fashion way. The cutoff line (or FOCUS) is adjusted so that the projector can be shipped with a sharp and crisp 'factory" quality line. Having a quality cutoff line is also mandatory for beam alignments when on the car. Other aftermarket (or plastic made!) bi-xenon projectors can sometime be a pain due a low quality (uneven) cutoff line. Hence the reason it is important for some to ensure that this is taken care of (of course it was).

Out of context: with a bi-xenon HID projector, there is nothing better to see ahead of you when you drive on bumpy surfaces. The cutoff line moves up/down like a laser scanner. I love love love it. Hard to explain in words but it kinda remind you how precise the Porsche suspension system is. Fancy set-up! (screw halogen forever for me).

Other features worth mentioning, and important for all responsible Porsche car owner, is the selection of a HID ballast. I am using the latest in terms of technologies available commercially. It is made by the most reputable manufacturer here in China and was recommended to me by the local professionals in the HID trade. It is a full Digital 35w canbus ballast with arc stabilizer, very low heat, protection features and EMC (Electro-Magnetic Compatibility). Meaning you can run the 20,000+volts right over your mobile phone and it will still receive and make calls without a single buzzing or circuit damage. Not cheap but it's Magic and mandatory for a Porsche car imo. No more flicking and annoying loud "ticking" sound noise coming out of your speakers when turning ON the headlights! I am very satisfied with this also being sorted.

If you have any question I'll be happy to answer them. Apologies if the above reply wasn't conclusive to what it was meant to achieve.

I am normally very humble about things in life but these are simply the "Ultimate Bi-Xenon Porsche projectors" (Carrera GT style as bonus!). I do these along with many other motorcycle and car aftermarket parts as a "hobby" and only would want to share the successes with other 986 owners like myself. It's not for profits believe me as running heavy CNC equipment for hours, carbide cutters, materials, imported dyes, using the best chemicals and paints, CO2 laser tubes, electricity, coolants, etc etc.... it all adds up very quickly. Profits are justified however very insignificant - it's just for fun really Be cool!


^ Here we go. My testing set-up. Yes it's a "3.6". I'll swap the burnt LED display in a few years maybe. This rectifier is getting olddd but still very good.


^ Here goes the cutoff line nice and crisp. Includes everything (arc and cutoff). Good enough for me and my Porsche car, it should be good enough for anyone (I am a picky PITA).


^ Another view from. Flat wall (3 meter far).


^ Try this with a substandard ballast and let me know if your phone still works after sparking them ON and OFF

[Nine8Six]

Temp of the ballast after a good 30 min of continuous operation. Very low heat generated - that alone is an excellent proof of quality.

Unlike previous hid ballast versions that used to run up to almost 90ºC (200ºF), or like Litronics(!), those can be hidden in the headlight's back compartment. Makes a perfect and clean headlight unit.

[Nine8Six]

Here goes a few shots of the complete set. Plenty of good fun and without being shy saying that those are the best looking Porsche headlights on the Internet ATM




^ The bezel/shroud face is fully customizable to your taste. Typeface can be changed and wording as well. Choice of paint or anodizing reflections styles available.


^ Shall you decide to go creative-crazy and want to dremel everything, plenty of abrasive wheels there. Also, I got a few emblems (badge) left so you are also helping me getting rid of those by getting a kit.

[steved0x]

Originally Posted by Nine8Six

^ Try this with a substandard ballast and let me know if your phone still works after sparking them ON and OFF

I am liking your phone!!

Steve

[BruceH]

Very nice work, impressive in fact! Thank you for the update, I found some clear halogens so now I have to decide if I am up to the task of installing these. After reading your detailed instructions, it doesn't seem too bad.

[Nine8Six]

Originally Posted by BruceH

Very nice work, impressive in fact! Thank you for the update, I found some clear halogens so now I have to decide if I am up to the task of installing these. After reading your detailed instructions, it doesn't seem too bad.

Thanks Bruce, compliment well received

Have a look at what member Blk986 has written RE opening the headlights. He make it look/sound harder than it really is but regardless, by far The best DYI on the subject anywhere atm. And unlike mine, this one is written in English!!!

DIY HID Projector Install instructions

All accurate info. Less the wiring set-up. No need for a load-lot-everywhere like Blk986.... (old method) the new ballasts today can simply be connected to the old H7 halogen connector. Just two little wires +/- (black & red). Can't go wrong there

Everything ballast related hides inside the back of the headlight unit. See nothing else but a BOSCH headlight. Clean & easy

[BruceH]

Thanks. My other decision is what color for the ring, but I will probably stick with the silver and keep the reflector stock. My car is Lapis Blue and I am sure the black would look great, but I think stock also looks great. I even kicked around the idea of a blue ring to match the Lapis, but long term, I think stock may be the way to go. Just thinking out loud. Any thoughts?

[Nine8Six]

Dunno mate. bear in mind it will never be 100% black during day time anyway, more like 50% gray with the sunlight reflections bouncing on/off the lens and all. That what's mine turned up to be if you look carefully. Just perfect design-wise. Night-time tho.... this is where this thing turns into a beast of its own

Day time you are looking at getting something like below. A brand New 2014 Boxster!



If you asked me, I'd say go for satin-black headlight interiors. With the outer silver trim left alone it will look perfectly balanced (your car color is already dark). The ring in silver - elegance first in your case.

If you had e.g. spoiler, side skirts, the futurist Gt3 front bumper, kinda style, then maybe I'd say go for the eccentric blue bezel.

Hope this helps a bit. Ask around what your friends and family think.... they know you better than I do!

[TeamOxford]

Originally Posted by Nine8Six

Day time you are looking at getting something like below. A brand New 2014 Boxster!

Why upgrade a 986 to a modernistic 2014 Boxster look?

There's something timeless and endearing about the design and patina of an older Boxster.

Just sayin'..................

TO

[Nine8Six]

Originally Posted by TeamOxford

Why upgrade a 986 to a modernistic 2014 Boxster look?

There's something timeless and endearing about the design and patina of an older Boxster.

Just sayin'..................

TO

Didn't meant to offend anyone or anyone's Boxster. I agree with you that old style headlights, battle scars, yellow'ed/burnt reflectors and all, can certainly add some character to any car.

RE the 2014 Boxster comment. As you can see from my whole thread... I am just having fun mate. Didn't really meant/believe that. I do however make it obvious that I'm all up for serious aesthetic improvements whatever it takes

[TeamOxford]

Originally Posted by Nine8Six

Didn't meant to offend anyone or anyone's Boxster. I agree with you that old style headlights, battle scars, yellow'ed/burnt reflectors and all, can certainly add some character to any car.

RE the 2014 Boxster comment. As you can see from my whole thread... I am just having fun mate. Didn't really meant/believe that. I do however make it obvious that I'm all up for serious aesthetic improvements whatever it takes

No offense taken.

The obvious quality of work you are producing is fantastic!

With all my cars, I have always appreciated what the original designer/engineer/team has offered. I guess I'm just a "clean-sheeter".

TO