Porsche Headlight Retrofit [from CAD, prototyping to finish)

[Evan_S]

Hi Nine8Six,

I'm a big fan of your work! Last weekend I was lucky enough to buy a used set from a fellow Dutchman. However, both lenses are not attached to the bezel/shroud anymore.

What is the (high-temp) glue that you used? Or is there another solution?

Thanks you in advance!

[Nine8Six]

Originally Posted by Evan_S

What is the (high-temp) glue that you used? Or is there another solution?

Hi Evan, thanks! yes I remember this chap, although I can't recall if those projectors were ever assembled and instead meant as a replacement for another set he had (he had the first ever set in silver if memory serves well!). I'm hoping those came with the H1 bulb mounting adapter and other hardware?

For the lens assembly you need a A+B epoxy rated/tested at 100dC. Surface preparation for both the lens and bezel requires decreasing with a pure acetone before bonding. Assembling and curing should be carried at room temp (indoor, 21dC).

ps. Welcome to the forum! Seen pics in the general section, great looking boxster

[Evan_S]

Originally Posted by Nine8Six

Ps. Welcome to the forum! Seen pics in the general section, great looking boxster

Thanks!!

Originally Posted by Nine8Six

l'm hoping those came with the H1 bulb mounting adapter and other hardware?

Yes, thankfully the kit is complete and still looks brand new!

Originally Posted by Nine8Six

For the lens assembly you need a A+B epoxy rated/tested at 100dC

Thanks, I'll look into it. Unfortunately most high-temperature a+b epoxy glues I found don't bond very well with glass. Maybe JB Weld?

I'm also thinking of using the type of angel eyes that I'm currently using as they automatically dim when you turn on the hid-lights. This is to prevent a blinding light-intensity at night, but maybe the hole-pattern in the bezel should be sufficient.

[Nine8Six]

Originally Posted by Evan_S

Yes, thankfully the kit is complete and still looks brand new!

Thanks, I'll look into it. Unfortunately most high-temperature a+b epoxy glues I found don't bond very well with glass. Maybe JB Weld?

I'm also thinking of using the type of angel eyes that I'm currently using as they automatically dim when you turn on the hid-lights to prevent a blinding light-intensity at night, but maybe the hole-pattern in the bezel should be sufficient.

Good news Evan. Was worried, I knew the kit was parted out but didn't remember if all parts we're shipped out. If you are missing anything just shoot me a PM and I'll get this sorted.

For the A+B, use this if you can get some locally. Will bond metals & glass and perform in both high & low temps (in the commercial grade epoxy anyway).

https://www.3m.com/3M/en_US/company-us/all-3m-products/~/3M-Scotch-Weld-Epoxy-Adhesive-DP420/?N=5002385+3293242436&rt=rud

[Evan_S]

Thanks again Nine8Six, you're a lifesaver!

[Evan_S]

Maybe I'm overthinking this, so forgive me if this is a stupid question...

When using the spacer, how is the projector assembly secured against the projector bowl with the tightening ring tightened?



Note, I don't have the tiny square in the projector bowl anymore, had to Dremel it away for the current projectors.

[Nine8Six]

Originally Posted by Evan_S

When using the spacer, how is the projector assembly secured against the projector bowl with the tightening ring tightened?

Note, I don't have the tiny square in the projector bowl anymore, had to Dremel it away for the current projectors.

Hi Evan, see if below visual is of any help to you. The missing tiny square isn't much of an issue although it would have been nice to have. In all honesty I've never tried fitting a set without it so trial & error apply here. Mount as per visual below first and see if you can level the beam projection high enough using OEM's adjustments in both X/Y axis. If all goes well with the beam adjustments, "Lock-Tight fluid" on the thread and move on! GL

Note: Its important to not exceed 23~23.5mm for the OD on the reflector's mounting hole.

[particlewave]

Originally Posted by Evan_S

Hi Nine8Six,

I'm a big fan of your work! Last weekend I was lucky enough to buy a used set from a fellow Dutchman. However, both lenses are not attached to the bezel/shroud anymore.

What is the (high-temp) glue that you used? Or is there another solution?

Thanks you in advance!

Every time I have to fix one of these, I use JB Weld.
Not one of my repairs has failed over the years.

[Nine8Six]

Originally Posted by particlewave

Every time I have to fix one of these, I use JB Weld.
Not one of my repairs has failed over the years.

You are getting me worried. Did you ever had anyone who've sent back their headlight for a repair on the lens?!? If so do you mind letting us know which member exactly please, just so I can keep track of failure rate and what needs improving, if anything at all. Thanks, Charles

PS. The kit you are looking at never had their lens mounted, hence Evan's question. The whole idea behind that parted-out kit was the member wanted to install his own angel eye kit and assemble the kit himself, which he never had a chance to do and sold the kit to Evan.

[PaulE]

Originally Posted by Nine8Six

You are getting me worried. Did you ever had anyone who've sent back their headlight for a repair on the lens?!? If so do you mind letting us know which member exactly please, just so I can keep track of failure rate and what needs improving, if anything at all. Thanks, Charles.

Hi Fred, the lenses on both of my projectors have come detached once and been repaired. The first one was repaired by Charles/Particlewave a couple of years ago, and the other one I repaired myself with some coaching from Charles. To be fair, my car was involved in a couple of front end fender-benders, and I'm not complaining. These are still awesome headlights and everyone who sees them loves them too.

You mentioned somewhere very recently that you're working on an improvement for the next version to secure the lens to the shroud with something mechanical, clips or screws, instead of glue. I think that would be a great idea. Right now I'm working on a spare set of headlights that will utilize Morimoto Mini H1 7.0. These projectors utilize a mount that clips right into the existing Halogen bulb socket. (I'm not using that feature this time, I am putting them in a set of Litronic reflectors). Have you ever considered just making a shroud that would be used in conjunction with the Morimoto Mini Bi-Xenon? It would simplify things for you, all you would need to worry about is the shroud, buyers would then just use it with the Morimoto parts they purchase on their own.

[Nine8Six]

Thanks for letting me know, Paul. Interesting though, why am I the last one to find out about this :/

You are correct, I'm working on revision of those same style projectors and this will include a lens adapter. Not much because of failure (I'm seeing <1% here) but more because I finally have means to do precision ID thread-milling operations with the new machine-tools I run here. An option that wasn't available at the time.

For the upcoming dev; I'm keeping the exiting CGT design, 2.5" lens config with same angle, aperture, H1 fitting, and will carry on using AES(company) improved version of those projectors you refereed too. ps. Paul, if we are to engineer some (new) car projectors & features it ain't going to be those dumb 1968 style lamps but more touching the areas of Adaptive Sense, Auto-Leveling and automotive led technologies. I've done quite a bit of studying on those subjects last year and may resume those research and prototyping in the near future. This would of course reach a wider market, not only Porsche.

Anyway. Some content for later. For now I'd like to pass my sincere apologies for the trouble this caused to you. if there is anything at all I can do to offset the burden please shoot me a PM and we'll find a way to square this issue. Thanks for letting me know and sorry to hear about your fender-benders :-(

[PaulE]

Thanks Fred, I'm looking forward to seeing your progress on any new lights and will order a set when they become available!

Originally Posted by Nine8Six

Thanks for letting me know, Paul. Interesting though, why am I the last one to find out about this :/

You are correct, I'm working on revision of those same style projectors and this will include a lens adapter. Not much because of failure (I'm seeing <1% here) but more because I finally have means to do precision ID thread-milling operations with the new machine-tools I run here. An option that wasn't available at the time.

For the upcoming dev; I'm keeping the exiting CGT design, 2.5" lens config with same angle, aperture, H1 fitting, and will carry on using AES(company) improved version of those projectors you refereed too. ps. Paul, if we are to engineer some (new) car projectors & features it ain't going to be those dumb 1968 style lamps but more touching the areas of Adaptive Sense, Auto-Leveling and automotive led technologies. I've done quite a bit of studying on those subjects last year and may resume those research and prototyping in the near future. This would of course reach a wider market, not only Porsche.

Anyway. Some content for later. For now I'd like to pass my sincere apologies for the trouble this caused to you. if there is anything at all I can do to offset the burden please shoot me a PM and we'll find a way to square this issue. Thanks for letting me know and sorry to hear about your fender-benders :-(