Porsche Headlight Retrofit [from CAD, prototyping to finish)

[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

[Nine8Six]

Originally Posted by davescott

Wicked thread

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

[jb92563]

Originally Posted by particlewave

Here's one or two...

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



^Hal 9000 from 2001 Space Odessy.

[particlewave]

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

[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?

[particlewave]

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.

Originally Posted by Nine8Six

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

[jb92563]

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]

Originally Posted by jb92563

Trying to figure out what would look best on a Black Boxster.

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

Originally Posted by particlewave

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]

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.

[BruceH]

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

[Crono0001]

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

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

[particlewave]

Originally Posted by Crono0001

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]

Originally Posted by particlewave

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]

Originally Posted by BruceH

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

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]

Originally Posted by Crono0001

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]

^thats what I was afraid of

[jb92563]

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...