Porsche Headlight Retrofit [from CAD, prototyping to finish)

[Nine8Six]

Originally Posted by kjc2050

Hello madmods!

lol Madmods, flattering thank you. I was a big fan.

I've heard from someone who knows Madmods very well that he received serious threats from a member (by PM) and one of those sadly included a death threat. From his posts & info, that same member managed to work things out and tracked him down to where he works. Unfortunately he sent additional threats using that channel. To be on the safe side Madmods decided to ghost his posts (and all details) including himself until this gets resolved. I was told he had to do the same thing on another forum he is member of (a working dog training forum).

What I've learn from his story; NEVER tell anyone that he drive a poor man' car with a complex of any sort, or initiate a thread on that similar subject. It can wake up a hater from the dead (fun), some other will simply be stalking (sick), or one can even become completely twisted and track you down (mental/dangerous).

And now, back to the GT style headlight DIY!

[Nine8Six]

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









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

/

[jb92563]

Originally Posted by Nine8Six

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



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

[Nine8Six]

Originally Posted by jb92563

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

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]

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


^ All starts with a completed bezel. In this case, the Great Gunmetal Gray style!



^ Once anodized and laser'ed with customer's custom script on the face, they are ready to be implanted an angel eye (lol)


^ 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)



^ 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.



^ 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.



^ 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.



^ This is the cavity that is machined inside the bezel to accommodate the angel eye, the filter & the diffuser.


^ Assembling in order: 1) clear acrylic first 2) opaque diffuser second 3) angel eye third 4) Thermal conductive epoxy resin


^ 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]

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

[davescott]

Wicked thread

[particlewave]

Originally Posted by Nine8Six

^ All starts with a completed bezel. In this case, the Great Gunmetal Gray style!

Amazing!

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 $

[jb92563]

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?

[Crono0001]

Originally Posted by Nine8Six

lol Madmods, flattering thank you. I was a big fan.

I've heard from someone who knows Madmods very well that he received serious threats from a member (by PM) and one of those sadly included a death threat. From his posts & info, that same member managed to work things out and tracked him down to where he works. Unfortunately he sent additional threats using that channel. To be on the safe side Madmods decided to ghost his posts (and all details) including himself until this gets resolved. I was told he had to do the same thing on another forum he is member of (a working dog training forum).

What I've learn from his story; NEVER tell anyone that he drive a poor man' car with a complex of any sort, or initiate a thread on that similar subject. It can wake up a hater from the dead (fun), some other will simply be stalking (sick), or one can even become completely twisted and track you down (mental/dangerous).

And now, back to the GT style headlight DIY!

Sorry to hear that, Madmods
Which forum member, by chance? I'd like to know so I can insult him personally on driving cheap Porsche :P

[Nine8Six]

Completed the 4th axis gcode and cutting. Needs a bit of adjustment so I'll have to run another prototype unit before doing the real thing next week. This proto is really to set the cutters, CNC machining gcode, and test the materials before doing the 'real pair'. When you have your stuff ready and all properly tested, things goes much faster when you do the real part. This will also assures that both sides will be identical.





Got the shroud clear anodized for 60min and paint sprayed it with VHT High Temp spray paint (Nu-Cast Aluminum P/N VHT SP995). The look & feel is the same as Arctic Silver and make the shroud look like a factory unit instead of a cheap machined shiny aluminum part. Anodizing is required to open the pores on the aluminum thus making a paint job permanent. It's becomes almost impossible to strip paint from anodized surfaces without the use of very strong chemicals (DRANO being one of them). Anodizing also makes the aluminum extremely strong and resistant to corrosion and further oxidation.

The anodizing and high temp resistant paint COMBO is the only choice for a durable part inside of what appears to be an oven. Closed headlights can become very hot during summer days so materials especially paints needs to be selected with extreme care - especially when converting to black like I'm planning to do. VHT and OMP both does quality heat resistant spray paints, VHT having a wider range of colours tho. Both brands are very expansive but using them guaranty nothing will peel off or flake on a hot summer day. Somehow priceless for Porsche headlights imo.


(camera flash was inappropriate here. Does look top quality when dry e.g. semi gloss arctic silver)

Until this prototype dries fully, does take a good 24-36 curing time, I am testing a another VHT painted aluminum/anodized surface I've prepared yesterday. Now it's just a matter of adjusting the perfect intensity on the Laser for a high resolution quality etching job. Yes, I plan on having a circular lettering pattern on the front of the shroud. Makes them look "brighter" (but not necessarily smarter lol).

[BugsFerBrains]

…last two pics, Porsche is mis-spelled.

[Nine8Six]

Originally Posted by BugsFerBrains

…last two pics, Porsche is mis-spelled.

Wow Thanks for looking You are the only one who picked it up lol

[woodsman]

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