Porsche Headlight Retrofit [from CAD, prototyping to finish)

[Nine8Six]

Originally Posted by AKnowles

That is looking really nice!

What really pays off on this mod is having cool members like yourself throwing nice compliments. Really appreciated. Cheers mate

Originally Posted by woodsman

nice work on the headlights. Very nice car- no one would ever guess it's year. What wheel size?

Same as yours Woodmans, I'm sure nobody can guess the year of your boxster. One thing for sure, the design of this car is timeless. Quoted from many members already but fun to reminded ourselves.

Wheels are 8.5" (ET40) front and 9.5" (ET40) rear with 235/30-19 & 275/35-19 rubbers. The rear arrives flush to the fender but I like it with a 15mm spacer. The fender to wheel arch follow-up is what makes this car rear-end look badass imo. Don't flame me on the 19" and '97 model too quick.... the wheels are as light as the stockers

Originally Posted by particlewave

Looking great! You did reserve a kit for me, right?

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.

Originally Posted by ohhh my

What's your secret on getting such nice clean and clear headlight lens without the yellowing from exidation? I have an 03 which have headlights newer than those, garage kept and it's yellowing... Please share.

A bit savage but there you go:

1) Wet sand with #1200 abrasive paper (carbide) (15min per headlight)
2) Wet sand with #2000 (30min per headlight - if you can't find #2000, ask a local jewelry shop where they get theirs)
3) Use a rotary pad/machine and buff them with the Maguire Headlight Restoration kit (a good 30-45min per headlight). Do this in a hot environment..... as in don't let the polycarbonate cool down when buffing them for the whole period.

It's a loooong and painful 2.5hrs job (lol) but as you can see, once done you won't be able to make the difference between an old unit and a NEW one

[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.

[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!).

[2000986s]

I cannot wait, the excitement is killing me hahah. Glad to hear about the script! I didn't see anywhere on the site to add that on so that's awesome you're doing it for all of them! Still waiting on my clear headlights to come in... Im starting to get the sick feeling I may have been screwed over by someone who was selling a used pair...

Wish me luck...

[jpc763]

Originally Posted by 2000986s

I cannot wait, the excitement is killing me hahah. Glad to hear about the script! I didn't see anywhere on the site to add that on so that's awesome you're doing it for all of them! Still waiting on my clear headlights to come in... Im starting to get the sick feeling I may have been screwed over by someone who was selling a used pair...

Wish me luck...

Did you buy that pair off of Ebay? From Canada?

[kjc2050]

Originally Posted by jpc763

Did you buy that pair off of Ebay? From Canada?

Look at post #1300.