Porsche Headlight Retrofit [from CAD, prototyping to finish)

[Nine8Six]

Originally Posted by Mikelove

Thats what im talking about! Thats the wow factor right there!

Thanks Mike! Can't wait to see your reaction when those GT style projectors are installed into a 100% black headlight unit, and on a 986

Originally Posted by 2003S

Been following this thread for a while, and I have to give you credit. I'm very impressed with the creativity and work that is going into this in such a short time. Nice work, they look really sharp. I can't wait to see the finished product.

Great encouragement, thank you Sir!

Originally Posted by SolidWorks Mike

Are you using SolidWorks to do the design and renderings?

Why I have a feeling that you know more than I do Maybe your Alias tells a lot!
The rendering capacity of SW is fantastic.

[SolidWorks Mike]

Originally Posted by Nine8Six

Why I have a feeling that you know more than I do Maybe your Alias tells a lot!
The rendering capacity of SW is fantastic.

I actually work for SolidWorks. Before I worked for them I used the software to design plastic injection molds.

It's always fun to see all the different things people design in SolidWorks.

Good looking models and renderings!

[Nine8Six]

Originally Posted by SolidWorks Mike

I actually work for SolidWorks. Before I worked for them I used the software to design plastic injection molds.

It's always fun to see all the different things people design in SolidWorks.

Good looking models and renderings!

I know Mike, you are famous in case you didn't noticed yet Hence my comment above (SW Mike alias, Las Vegas, etc... not a hard guess).

I regularly see you on SolidWorks World's Stage presenting. Big fan of it and make sure not to miss it every years. Nice work to "you guys", period.

Didn't know you were drriving a Boxster tho. That is good news. I'll make sure to request help from you if this happens. How could you refuse to help out a fellow boxster owner LOL

Good to see you here!!!

[Nine8Six]

The projector's mounting design is final. The prototype machining is completed and the assembly have been tested. Again, all carried out with emphasis on simplicity (Plug&Play), lightweight, and rigidity.

A 40mm spacer between the projector and the headlight reflector was required. Without the spacer the whole assembly was hidden (tucked) inside the reflector. Now the shroud's features can be viewed from most angles; top, front and sides. Looks absolutely fantastic (pics of this coming soon).

For now, here goes the model and other visuals of the projector mounting assembly.












^ This is how the kit comes really (and will ship). How easy!


^ The kit after anodizing. Yes I anodize everything but for good reasons:
1. the parts last a decade (min) without showing any sign of fading
2. the anodize layer is extremely hard, making the aluminum parts and their finishes indestructible
3. non-conductive surface. when anodized, the part lose its conductivity feature. A must when engineering parts near electrical systems.

Now off the headlight preparations & painting. I'll update as soon as I can

/