Porsche Headlight Retrofit [from CAD, prototyping to finish)

[Jamesp]

I replaced mine as it was getting finicky working sometimes, and sometimes not. Replacing it is very easy.

[strachan]

Thanks for the quick responses. Pulled everything apart, put it all together and still doing it. Now one light isn't even sparking (lightning). New switch ordered.
Will post again after new switch is installed.

[strachan]

Originally Posted by strachan

Thanks for the quick responses. Pulled everything apart, put it all together and still doing it. Now one light isn't even sparking (lightning). New switch ordered.
Will post again after new switch is installed.

The switch going bad...would that also make the stereo get staticky when the switch is in the on position?

[Jamesp]

Any poor connection arcing could do that.

[amagalla]

OK. I just received my projectors from Pelican, and on initial inspection, It looks like there might be some debris in one of the projectors. Is this normal? Do I have to disassemble them to clean them out? Are there instructions to disassemble them? I would imagine that the heat of the bulb will cause the debris to damage the projector.

Second issue/question. How do you feed the projector solenoid and angle eye wires through the reflector?

Last thing. These came with the kit:



I assume they go to the angel eyes, but what are they?


Thanks

Tony

[clickman]

There should be no debris in the projectors. I wasn't careful enough during my installation and got dust inside one of them. You can remove the inside screws to get it apart and very carefully clean the inside. Getting the screws back in can apparently be a PITA, although I found it easy.

I did not have the angel eye option. The solenoid wires (and presumably the angel eye wires) go thru the little rectangular opening under the projector, shown on page 17 and 18 of the instructions.

My kit did not have the wires you show.

[particlewave]

Yes, you should clean thoroughly right before install. Debris inside from shipping is normal because they are not sealed units. There are 4 screws that hold the lens portion on the reflector.

The picture you posted shows the angel eye voltage regulators.

[particlewave]

Originally Posted by Nine8Six

by Norm (member Clickman) & Charles (member Particlewave)

Excellent News

We now have a complete DIY Installation Manual for those who wish to upgrade their Porsche Boxster (986) or Porsche 911 (996) old halogen headlights with a true bi-xenon & HID lighting system. The manual is completed with 29 pages, 27 HD pics and one video.

Can't thank Norm and Charles enough for helping me out for putting this together. And it's in English! Thank you

Download [3MB]:
http://www.gtprojectors.com/downloads/Porsche_986_996_Headlight_Retrofit_Instructions.pd f




^ The Ultimate Exterminate the Halogen Manual!

..........

[CHRISP357]

The do it yourself guide is really only one step long.
1: send to Particlewave.

[amagalla]

Just opened the lens, cleaned it with alcohol, put it back together. No sweat. Does the connector for the angel eyes stay inside the reflector? It doesn't seem long enough to exit the reflector bowl.

[particlewave]

It should be just long enough to reach through. If not, untwist the wires. I'm not sure it will fit through the small square hole, though. I always use the larger parking light hole.

[particlewave]

Originally Posted by CHRISP357

The do it yourself guide is really only one step long.
1: send to Particlewave.

......

[amagalla]

The blue and white wires weren't long enough to exit the through either the parking light hole or the deflector hole. So, what I ended up doing is extending the length of the blue an white wires, removing the plastic plug, feeding them and the black and red wires through the square deflector hole, and putting the plug back on.

Another problem that I have to figure out how to deal with is baked lens debris sticking to the inside of the outer lens. I'm not sure how to get this stuff out without scratching it.

[particlewave]

Wash your hands with hot water for a good 2 minutes to soften the skin. Scrub your fingertips with a scrubber to remove any dead skin.

Lay the lens over the sink (inside up) and fill with warm water and a good 2 tablespoons of dawn dish soap. Add the soap after the water so that it doesn't cause a lot of bubbles. Use your fingertips to lightly wash the inside of the lens and rinse with warm water. Use compressed air to blow all water out.

This is the method I use with every set that I do and it never causes scratches.

[amagalla]

Just finished all the wiring for both headlights. Getting close now. I just have clean and seal the lights.

Tony

Sent from my SM-T800 using Tapatalk

[amagalla]

These are the lenses that I started with.



There is actually a hole burned into the passenger lens.

This is where they are now:



The last steps are to clean the inside of the second drive side lens (passenger side done already) , seal the lenses, and polish the out side.

I'm also looking to add CREE LED towers as the high beams and the fogs. any recommendations?

Almost there.

[mikesz]

that is amazing! Great job!

[amagalla]

I finally got all of the pieces in place to finish the headlight upgrade (was waiting for the corner pieces and the LED bright and fog lights). Here is what they looked like before:




Both headlights are in really good shape. But this looks so much better:
New

vs. Old


There is a notable difference in the headlight housing itself. If you look closely, you can see that there is a sort of diamond pattern on the inner shroud of the new headlight in front of and just below the projector. I mention this because if I had not bought these as a set, it's possible that you could end up with two different housings.

Here is a head on view:



Man, these look so cool.

Tony

[BruceH]

^^^Very nice, looks great

[particlewave]

Nice work, Tony!