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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)

Nine8Six 01-04-2014 06:24 AM

Pictures of the Boxster & Projectors under the Yan'An blacklight
 
It's weekend out for the Porsche here!!!

Had to park 1 min at the corner of Yan'an and Nanbei elevated roads for a quick photo snap. Please don't blame me for loving that car so much (and of course those projectors)... the Boxster only comes out of its garage once a month.

986 Disco anyone?!

http://986forum.com/forums/uploads01/011388848550.jpg


http://986forum.com/forums/uploads01/021388848742.jpg


http://986forum.com/forums/uploads01/031388848762.jpg



The 986 is parked somewhere under there. This city is mental on Saturday night (blacklights ON).
http://986forum.com/forums/uploads01/041388848783.jpg

BruceH 01-04-2014 06:36 AM

Great looking pictures! Once a month?:(

Nine8Six 01-04-2014 06:44 AM

Quote:

Originally Posted by BruceH (Post 379513)
Once a month?:(

Sadly :/ I also have a very nice VW Passat

My favorite, a nice plastic Public Transport card!

http://img3.cache.netease.com/photo/...9E00AP0001.jpg

Jamesp 01-04-2014 01:52 PM

Quote:

Originally Posted by Nine8Six (Post 379514)
Sadly :/ I also have a very nice VW Passat

My favorite, a nice plastic Public Transport card!

http://img3.cache.netease.com/photo/...9E00AP0001.jpg

Are the roads outside the city of high enough quality to run your Boxter? Seems like either they would be there new and awesome, or not at all. And you car rocks, kind of goes with the city. Love your style.

BruceH 01-04-2014 01:56 PM

Quote:

Originally Posted by Nine8Six (Post 379514)
Sadly :/ I also have a very nice VW Passat

My favorite, a nice plastic Public Transport card!

http://img3.cache.netease.com/photo/...9E00AP0001.jpg

:eek: Ok, now I understand.

Leebherron 01-04-2014 02:25 PM

City lights !
 
Awesome city pics Fred. Love it. Yup plastic diped headlight rims. If I don't want I just peel it off ! Lee

particlewave 01-04-2014 10:11 PM

Quote:

Originally Posted by Leebherron (Post 379134)
Finished, looks quite hot (red) !
Thanks Fred
http://986forum.com/forums/uploads01...1388633231.jpg

Looking good! :cool:

particlewave 01-04-2014 10:15 PM

That lighting makes some nice pictures! :D
Amazing :cool:

Nine8Six 01-05-2014 11:07 AM

Quote:

Originally Posted by Jamesp (Post 379571)
Are the roads outside the city of high enough quality to run your Boxter? Seems like either they would be there new and awesome, or not at all. And you car rocks, kind of goes with the city. Love your style.

Hey James. Nah the roads in China are some of the best in the world. 50% of them are <10years old. Sure some are much old however extremely well maintained. Mind you, a Shanghai private car plate (required for locals, and foreigners as well of course) cost US$13,492 (or CNY85,000). With 25million residents, many of those owning cars, believe when I say the dept of transport has a great financial support and deliver quite well in that respect.

The inter-provincial roads/freeways being by far the best and coolest (not a single 1" wide crack in those). They use a sort of high abrasive asphalt -mix- with concrete. Those are the ones that my Boxster sees the most frequently really (monthly!).

http://986forum.com/forums/uploads01...1388952055.jpg

^ We also have the ring in SH! Can't see clearly but there are 3 levels on that ring. This is the first time my little Porsche have seen human vomiting.... I was ramping down at over 150kmph (the guy who barf'ed in my car is not my friend anymore). I normally (rarely) never exceed legal speed limits... talking karma huh

Nine8Six 01-05-2014 11:16 AM

Quote:

Originally Posted by particlewave (Post 379631)
That lighting makes some nice pictures! :D
Amazing :cool:

Really glad to see you back, was worried actually.

2014 should be good for all... make great use of it brotha :cool:

heliguy 01-05-2014 12:25 PM

Quote:

Originally Posted by Leebherron (Post 379134)

The red looks good. Also the black around the headlight, why didn't you go all the way around with it?

Nine8Six 01-05-2014 12:29 PM

I'd quickly remove that plasti-dip and paint them permanently if I were Lee. Does look bad a**

alanqning 01-06-2014 08:11 AM

I need to visit Shanghai sometime soon, this looks awesome. I'll try and get in contact with you if I do.

Quote:

Originally Posted by Nine8Six (Post 379698)
Hey James. Nah the roads in China are some of the best in the world. 50% of them are <10years old. Sure some are much old however extremely well maintained. Mind you, a Shanghai private car plate (required for locals, and foreigners as well of course) cost US$13,492 (or CNY85,000). With 25million residents, many of those owning cars, believe when I say the dept of transport has a great financial support and deliver quite well in that respect.

The inter-provincial roads/freeways being by far the best and coolest (not a single 1" wide crack in those). They use a sort of high abrasive asphalt -mix- with concrete. Those are the ones that my Boxster sees the most frequently really (monthly!).

http://986forum.com/forums/uploads01...1388952055.jpg

^ We also have the ring in SH! Can't see clearly but there are 3 levels on that ring. This is the first time my little Porsche have seen human vomiting.... I was ramping down at over 150kmph (the guy who barf'ed in my car is not my friend anymore). I normally (rarely) never exceed legal speed limits... talking karma huh


Kenny Boxster 01-06-2014 11:35 AM

Wow, Shanghai has changed a lot since I last went. Need to go visit soon!

alanqning 01-06-2014 11:47 AM

Quote:

Originally Posted by Kenny Boxster (Post 379835)
Wow, Shanghai has changed a lot since I last went. Need to go visit soon!

986forum roadtrip? We can all get our cars transported to China, it'll only be a few hundred dollars each way right? :rolleyes:

Jamesp 01-06-2014 05:30 PM

Quote:

Originally Posted by alanqning (Post 379837)
986forum roadtrip? We can all get our cars transported to China, it'll only be a few hundred dollars each way right? :rolleyes:

Well any other car would be a few hundred bucks, but a Porsche, well that's several tens of thousands.

davescott 01-06-2014 08:05 PM

Hi Nine8six, saw your projectors on J. Mitro 996 this weekend. Best mod I have ever seen

I have the black 996 and *need* this kit on my car. What is your paypal address?

I want the white angel eye if available

http://986forum.com/forums/uploads01/021386628322.jpg

jb92563 01-07-2014 06:50 AM

Quote:

Originally Posted by Nine8Six (Post 361664)
I still haven't received the clear headlights. Customs clearance seems to be an impediment and take longer than I thought it would.

A bit of progress. I've started on the shroud prototype for the projector. Took delivery of the AL 6061 T6 billet stocks at 19:00 and had to spin one of them on the lathe that same evening! The high pitch and regular techno beats those machines makes is excellent for relaxation ;)

Here goes a few shots... classic entertainer

http://986forum.com/forums/uploads01...1378472571.jpg

Here goes the shroud, unfinished. Still got to write a few gcode lines and off to the 4th axis!
/

These look great!!!

Funny, when I first saw this post during a search I thought someone was recycling aluminum pistons into Headlight projectors ...LOL

Not a bad idea actually if you can get the right size pistons.

This Porsche mod obsession is crazy. Now that I have burned out a low beam bulb, I'm considering projectors :p

Nine8Six 01-08-2014 04:24 AM

Quote:

Originally Posted by davescott (Post 379903)
Hi Nine8six, saw your projectors on J. Mitro 996 this weekend. Best mod I have ever seen

I have the black 996 and *need* this kit on my car. What is your paypal address?

I want the white angel eye if available

PM sent. Thanks Dave and looking forward

Nine8Six 01-08-2014 04:31 AM

Quote:

Originally Posted by jb92563 (Post 379921)
These look great!!!

Funny, when I first saw this post during a search I thought someone was recycling aluminum pistons into Headlight projectors ...LOL

Not a bad idea actually if you can get the right size pistons.

This Porsche mod obsession is crazy. Now that I have burned out a low beam bulb, I'm considering projectors :p

LOL recycled piston. Great idea tho!

See, now that you have a burned bulb, you MUST upgrade for a set of those projectors. Halogen is dying, the price of bulbs will quadruple within months, soon you won't be able to find them anywhere anymore, you and your boxster will be both left alone in total darkness.

Long life to modern xenon lol

Joking aside, I'll be very happy to make a kit in the very best of my capacity for you. Give me a shout when you're ready to crack on

Nine8Six 01-08-2014 04:40 AM

Angel Eyes (in the making w/ specs and pictures)
 
Few of you guys requested some more info about the optional angel eyes kit RE how they sit the bezel, material used ect. Someone else reminded me about the theme of this thread, which is to document every steps taken in the making of those high performance projectors, w/ pictures of course! Fair enough I'll say ;)

http://986forum.com/forums/uploads01/011389187938.jpg
^ All starts with a completed bezel. In this case, the Great Gunmetal Gray style!


http://986forum.com/forums/uploads01/021389187945.jpg
^ Once anodized and laser'ed with customer's custom script on the face, they are ready to be implanted an angel eye (lol)

http://986forum.com/forums/uploads01/031389188231.jpg
^ Somebody is missing his early high school years obviously. However most material you see there have been fine selected and thoroughly tested.
- 2mm thickness acrylic color filters
- 0.1mm thickness photography LED light diffuser film (very expansive, $4 per sheet, doesn't change color due to heat or time, ultra thin and 100% opaque)
- A set of COB LED angel eyes in white color
- Top quality Thermally Conductive Epoxy Resin/filler (A+B) and application syringe. (I get this for free knowing someone close to me working in this industry haha)


http://986forum.com/forums/uploads01/041389187962.jpg
^ In this case I'll be using a clear acrylic filter for white angel eyes. But I have them is pretty much all other colors! They all create a very soft but vivid light output.


http://986forum.com/forums/uploads01/051389187969.jpg
^ I've tested many different types of angel eyes COB LED rings during the whole of December. Those are the best you will find in the world at the moment. The 90 LED are covered by a resin (no vibrations) and the circuit is built-in to the PCB.

One LED goes off and you still have 89 working! This + a 2mm thick filter and you are certain that the angel eyes' light output won't be broken or affected by a burnt led.

They are rated @ 20,000hrs and known as The Best in the industry.


http://986forum.com/forums/uploads01/061389187979.jpg
^ They also come with the proper heat resistant wiring, both the angel eye and wiring passed tests @ ~300 ºF for 120min continuously (amazingly).
Decent connection are in already place however everything gets re-enforced later with thermally conductive resin.


http://986forum.com/forums/uploads01/071389187988.jpg
^ This is the cavity that is machined inside the bezel to accommodate the angel eye, the filter & the diffuser.

http://986forum.com/forums/uploads01/081389188000.jpg
^ Assembling in order: 1) clear acrylic first 2) opaque diffuser second 3) angel eye third 4) Thermal conductive epoxy resin

http://986forum.com/forums/uploads01/091389188009.jpg
^ Final assembly covered with a few drops of the thermally conductive epoxy resin. The thermo epoxy resin is rated @ ~500 ºF

* ZERO light escape from behind there, no lens light pollution
* Vibrations proof, no movements, no condensations, no hot spots along with effective heat dissipation materials. MAX temp emitted from the angel eye is 90~96 ºF (or 36 ºC). Very low!
* Safe, stable and durable along with a stunning natural looking & diffused light output.

The most advanced and simplest angel eye design you'll ever see.

There you have it!

Nine8Six 01-08-2014 05:11 AM

Just an updated diagram of how thing hooks up to the existing Porsche 9X6 headlight wiring.

http://986forum.com/forums/uploads01...1389190254.jpg

davescott 01-08-2014 06:07 AM

Wicked thread :cheers:

Nine8Six 01-08-2014 10:44 AM

Quote:

Originally Posted by davescott (Post 380032)
Wicked thread :cheers:

Must be the Quebecois frenchglish ;) I'm trying to use as many pictures as I can... helps to cover up spelling mistakes lol

jb92563 01-08-2014 04:05 PM

Quote:

Originally Posted by particlewave (Post 375407)


I wonder what single pulsating red LED would do inside the projector with the HID off. Perhaps a security light like on the dash?


http://stream1.gifsoup.com/view2/4406659/hal-9000-o.gif
^Hal 9000 from 2001 Space Odessy.

particlewave 01-08-2014 04:57 PM

^ I like that idea...I may have to take it ;)

http://i875.photobucket.com/albums/a...1943A23B8B.jpg

http://i875.photobucket.com/albums/a...D6E8921254.jpg

particlewave 01-08-2014 09:15 PM

Quote:

Originally Posted by Nine8Six (Post 380028)
http://986forum.com/forums/uploads01/011389187938.jpg
^ All starts with a completed bezel. In this case, the Great Gunmetal Gray style!

Amazing! :cool:

I must own these. I have no say in the matter. I must have them.

I have another set of amber headlights that I'm thinking of converting as the outer lenses are in much better shape than my current "clear" set...now you're giving me a reason ;)

I may have to return some Christmas socks to scrape up the $ :D

jb92563 01-08-2014 09:49 PM

When the running lights are on but not the headlight switch my headlights emit a dim light.

Is that from a small seperate bulb or do the hight or low beams get lit with reduced voltage through a resister?

I was wondering if this is an issue for the projectors or if that is not the same circuit that the projectors use?

particlewave 01-08-2014 10:01 PM

That dim light is a small running light, separate from the high and low beams.

It is the smaller third bulb to the right in this picture and it's what we use to power the angel/devil eyes.

Quote:

Originally Posted by Nine8Six (Post 380030)
Just an updated diagram of how thing hooks up to the existing Porsche 9X6 headlight wiring.

http://986forum.com/forums/uploads01...1389190254.jpg


jb92563 01-09-2014 06:05 AM

Ahaa, I was wondering about that, thanks for clearing up that question.

I also wondered about the CANBUS Ballast.

Does a 2001 Boxster S have a CANBUS connector that plugs into the Ballast?

I thought I read some where that 2003+ only use the CANBUS stuff.

I haven't replaced my burn't out low beam Halogen bulb yet as I'm getting ready to pull the trigger on these Projectors.

Trying to figure out what would look best on a Black Boxster. I'm leaning towards the Silver or Red bezel, since I have Red calipers and Silver wheels.

I'll have to do the pulsating red LED as well behind the lens to give it that "Dragon Eye" look at night. It should be hooked up with the security LED so that it does its thing when armed.

Nine8Six 01-11-2014 09:31 AM

Quote:

Originally Posted by jb92563 (Post 380159)
Trying to figure out what would look best on a Black Boxster.

JB, PM sent! Let me know when you are ready

Quote:

Originally Posted by particlewave (Post 380133)
I have another set of amber headlights that I'm thinking of converting as the outer lenses are in much better shape than my current "clear" set...now you're giving me a reason ;)

W/ green angel eyes for sure ;) Got those bad boyz standby for you whenever you are good to go Charles

Nine8Six 01-11-2014 09:44 AM

Angel eyes pictures
 
Those are a set of white angel eyes. Hate shooting at low ambient lighting... just never works. It does however give a good idea of that unique dotted pattern with the double reflection effect in the clear lens. The angel eyes are white themselves however some of the reflections have a very light blue'ish tint. Looks extremely modern.

below is just an overview of what it would look like while having the parking light ON alone. Looks pretty slick with both angel eyes and HID turned on - should have pics of that coming soon.

http://986forum.com/forums/uploads01/011389465418.jpg

http://986forum.com/forums/uploads01/021389465426.jpg

http://986forum.com/forums/uploads01/031389465433.jpg

BruceH 01-11-2014 10:32 AM

^^^^You are killing me;) Those look incredible, I am going to have to pull the trigger soon:cheers:

Crono0001 01-11-2014 03:02 PM

I might need to have someone custom fit these into my already LED happy headlights.

VOLUNTEERS?!!! I SHALL PAY FOR LABOOOORR!!

particlewave 01-11-2014 05:12 PM

Quote:

Originally Posted by Crono0001 (Post 380535)
I might need to have someone custom fit these into my already LED happy headlights.

VOLUNTEERS?!!! I SHALL PAY FOR LABOOOORR!!

Sorry Crono...I wasn't ignoring you, just been thinking the project over. The only thing that has me worried is the quality/durability of the housing and outer lens on those units. I've never seen a set in person, so I'm not sure.

I'd like to try to find some info regarding the strength and melting point of the plastic...

Crono0001 01-11-2014 09:12 PM

Quote:

Originally Posted by particlewave (Post 380553)
Sorry Crono...I wasn't ignoring you, just been thinking the project over. The only thing that has me worried is the quality/durability of the housing and outer lens on those units. I've never seen a set in person, so I'm not sure.

I'd like to try to find some info regarding the strength and melting point of the plastic...

Sent you a PM.
You're going to be stabbing in the dark. I'll try to get some info from my supplier, but I highly doubt I can get you much.

Nine8Six 01-11-2014 11:32 PM

Quote:

Originally Posted by BruceH (Post 380484)
^^^^You are killing me;) Those look incredible, I am going to have to pull the trigger soon:cheers:

Hey Bruce, glad you like these ones mate. Not only they are killing nice & functional but also 'very expansive looking'. Nice mod in all honesty. Most of that expansive looking effect coming from the gunmetal finish/color I personally think.

Get a kit while the offer last is my best advice to you ;) Read "Limited Edition"

Nine8Six 01-11-2014 11:41 PM

Quote:

Originally Posted by Crono0001 (Post 380579)
Sent you a PM.
You're going to be stabbing in the dark. I'll try to get some info from my supplier, but I highly doubt I can get you much.

Crono - I've recently seen those aftermarket headlights that you have. Unfortunately they are not serviceable like the oem Porsche headlights. The lens are "glued" to the housing (permanent). Genuine Porsche headlights uses a silicon base seal which makes it extremely easy to open or service.

Your best bet is, if you are serious about upgrading to high performance projectors, is to find a set of (used) Porsche headlights and retrofit those instead.

If your aftermarket headlights are still in good condition you could sell those and that should be more than sufficient to cover the cost of your entire retrofit (that incl a set of used Porsche headlights!).

Just an idea for you mate

particlewave 01-12-2014 12:37 AM

^thats what I was afraid of :(

jb92563 01-13-2014 11:41 AM

Nine8Six, if I get a set of these but without the Angel Eyes LED option will I still get the Bezels with the holes for the Angel eyes?

I'd like the ones with those holes so I can always upgrade later on in case I do want angel eyes later on.
Plus they just look great with the holes in any case and it saves some weight...;)


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