Porsche Headlight Retrofit [from CAD, prototyping to finish)
 

I am currently designing a set of Porsche headlights for my guard red boxster 986 and thought it would be cool to share with other members as I go along with the built.

I will be using the famous clear BOSCH headlights found on most Porsche Boxster 986 year 2002-2004. P/N: 986 631 131 14 and 986 631 132 14. I've ordered a spanking NEW set of those and likely to receive them this Thursday (if FedEx is not lying to me).

The first step is to design a custom projector shroud (aluminum) for the aftermarket bi-xenon projectors that I got. Next will be to make a sleeve (1mm PVC cylinder) that goes from the shroud down to the stock reflector. The goal with this design is to ensure that there is no light or any glare coming out from the back of the headlight. I need 1 (one) source of light coming from the projector lens alone. In other words, I am after a quality beam of light.

As you can see from my initial CAD design, I am borrowing the Carrera GT headlight style for the projector's shroud design, but using a 2.5" lens instead of the stock GT Carrera huge 3.5".

I'll post more pictures and what I am doing soon enough. I'll be turning the stock aluminum in the lathe and carry out 4-axis CNC operations on the shrouds as soon as this coming weekend.

Below is the initial CAD work. The black dish holding the whole assembly is the OEM chrome reflector found in the BOSCH headlight (to be soon painted in matte black). It will look better when all assembled in the headlight no worries!

http://986forum.com/forums/uploads01...1378216490.jpg

http://986forum.com/forums/uploads01...1378216507.jpg

http://986forum.com/forums/uploads01...1378216527.jpg

http://986forum.com/forums/uploads01...1378216547.jpg

http://986forum.com/forums/uploads01...1378187466.jpg

You might want to check out this thread,

http://986forum.com/forums/performance-technical-chat/29313-custom-headlights-conversion-litronic-style-w-pics.html

Excellent thread and information. Very kind, thank you so much :cheers:

Hello madmods!

SHhhhhhhh!:p

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!

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

http://986forum.com/forums/uploads01...1378472558.jpg

http://986forum.com/forums/uploads01...1378472571.jpg

http://986forum.com/forums/uploads01...1378472585.jpg

http://986forum.com/forums/uploads01...1378472598.jpg

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

/

Cant wait to see how these turn out

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

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.

http://986forum.com/forums/uploads01...1378489420.jpg

http://986forum.com/forums/uploads01...1378489435.jpg

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.

http://986forum.com/forums/uploads01...1378489460.jpg
(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).

http://986forum.com/forums/uploads01...1378489482.jpg

http://986forum.com/forums/uploads01...1378489497.jpg

Next step, in the oven at 200degree for 72hrs nonstop. Hope those parts and etching, edges, etc will pass the test.

If it comes out well, would you make a pair for sell?

/another red boxster that needs some new headlights...

Should look just like the Carrera GT kit (right lol!)

If not, it will be close enough. The idea of having a 30degree chamfer on the face is to simulate the "angel eye" effect. The light bouncing on the 30 degree edge make these quite unique looking - its just perfect and clean imo.

Sneak peek below (taken on a 25watts desk lamp). Sick under HID trust me. Just too lazy to plug in the HID kit again, I've just put it away two hour ago. You'll get the idea I'm sure.

http://986forum.com/forums/uploads01/aEye1378492835.jpg

I got a C-GT about 2 miles from my place and I always see this guy during the weekends or at the track. He drives me nuts and single-sided deaf each time he revs up next to me with his titanium straight pipes :/ Wait until he sees MY headlights lol

I'm building this GT headlight based on one specific bi-xenon assembly. Meaning you'll need the same kit: 2x GT style shrouds + 2x bi-xenon projectors. Still cheap no worries there. Not super high tech as you can see.

Any retailed HID lighting can be used to fire up the kit I'm guessing.

Let's talk when completed. I may send this design to a manufacturer if a few of the 986 and 996 guys are interested. For now let's hope all turn up to be what it should ;) Wish me luck.

Can't wait to see the final product!

non mais putin this is amazing. If the result is really like on the picture then I want you to make a kit for me also. I know the mean and elegant look of the carrera gt it is exactly as on your picture. well done replicating this for the normal Porsche

also cant wait to see this happening. subscribed

I would be interested in a pair if you develop for sale.
Great project!
Van

Teaser for the moment. This is where I'm going with that project.

Already looking good from the picture so in theory, it should looks even better in real life :) Everything is cooking for another 2 days so I'll take the weekend off on this one. I'll get back to work this coming Monday or Tuesday evening. Hopefully I should have received the headlights by then.

http://www.multilogik.com/986forum/bhid4.jpg
(Picture credit goes to member Boxster7614. His built with the black interior was my main source of inspiration).
See his thread at: Black HIDs

Very much alike but not the same. The GT's has two angel eye effects on its shroud, mine will be limited to one. Not a huge fan of super bright front-end anyway.

Reusing the main source of light for the angel eye makes it what it is indeed! I certainly agree with your "elegant" point.

:cheers:

2-4weeks max project. I'll keep updates coming

Thanks Van

Interested in a set if you sell one

Sent from my SAMSUNG-SGH-I747 using Tapatalk 2

Thanks for the support, nice one!

Ok, I'll run a batch on those and list them on my ebay for grab. Of course I'll keep you Reiver, Takart and Van on priority no worries.

I don't like the led or halo eyes that is why i'm interested in your idea very much. by the way your concept pictures are on the french porsche forum now. haha sorry. a few of 996 guys want to talk with you. send you the link by pm

your last picture with the red boxster headlight style. look really good. I can confirm now that I want to buy the kit when it's ready. Keep me inform please

looks good

i've been looking for a way to convert my 987 foglights to good LED like modern porsches have.

Cayman LED Spars with Radiator Guards (fits 2006-2008) Group Buy - was making some for the cayman and offered to make some for the boxster but there wasn't enough interest

It always amazes me how motivated some people are! Awesome!

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the only pattern we see is this some other will simply be stalking (sick). I think you need some serious help woodsman

THANK you. I did like you and order the headlights same with the white corner. please keep us updated. did you get my pm?

Hmmmm I just saw this interesting topic !
I would like to see the result in real life if it's not a problem.

For my two cents worth, all I can say is very impresive indeed.

Seriously nice work! :cool:

Finally done selecting the paint after completing a non-stop 67hrs cooking session at 225degree on two different unit. Without a peel or a single bubble. I'm pretty convinced the unit will be able to endure a few years of medium to hot weather.

*Design update*

I've designed a custom lens mounting system to achieve a simpler assembly. Therefore no more fitting PVC cylinder and gluing shroud ideas! What I got now is a solid and lightweight aluminum complete unit. Installation should be as easy as replacing a light bulb.

Other than that not much more. I've shorten the shroud by 10mm making it look a bit more like the Carrera GT lens. It's now 30mm in length. Looks far better imo

http://986forum.com/forums/uploads01...1378844317.jpg
See through view. I haven't bothered to model the cutoff plate and the solenoid. They do not interfere with the design so pointless to waste time there.

http://986forum.com/forums/uploads01...1378844326.jpg
Sliced view of the assembly. The weird box inside is are only proportions and represents the compartment for the solenoid ie. the coil that activate the cutoff plate (high/low beams flip flap thingny).

http://986forum.com/forums/uploads01...1378844334.jpg
How the unit will be assembled. The four tabs of the skirt will be secured with SS304 M4 screws, shroud and lens mounted with 1,300 degree high temp industrial epoxy (very expansive stuff, and unforgiving).

http://986forum.com/forums/uploads01...1378844345.jpg
The back view. I've left two ventilation ducts. Unfortunately I am being told by the manufacturer of the projector that the unit can't be closed completely. This is to ensure the longevity of the HID bulb.

http://986forum.com/forums/uploads01...1378844354.jpg
Rendering of the assembly. This is the whole unit really. Clean and Plug-&-Play!


Will update as it goes. Moving on to shopping for materials tomorrow, CAM work thursday and production on Friday eve and (very possibly) the weekend as well. We'll see how things pans out here.

The guy to ask here is Particlewave. Having seen a few of his threads and DIY, he clearly knows more than anyone in the trade RE this kind of stuff.

Passion for whatever you do is key. Motivation, call it the way you want. Thanks!

You go too fast for me Takart but I appreciate the support. Cheers mate. PM replied (ouch).

Don't see any problems, of course.

Mostly fun and relaxing project mate. The real impressive stuff is locked away on an encrypted hdd ;)

Thanks for looking guys. great encouragement, great forum, brilliant people!

Looking forward to seeing the finished product!!!

These look great!
Congrats on your work.
Van

Nine8six, do you have a Canadian car with stock Daytime Running Lights?

The non-DRL folks are wiring low beam wires to the projector bulb and splitting off the high beam power to the cutoff shield solenoid. Easy.

HOWEVER, the stock DRL uses the low beams, supplying reduced voltage to the lows in DRL mode, which would be an issue for the projector. HID Vendor: The reduced DRL voltage generally isn't compatible with aftermarket HIDs, but with some advanced configuring you should be able to set it up.

If you have stock DRLs I'd love to know how your going to work it.

The lights are coming along great! awesome! I want to know what software your using to draw these images ??

My litronic equipped Canadian car delivers batt voltage to the capacitor's plug in point as soon as the car starts. Maybe all you need then is a DRL relay/ CU from the lit set-up. I just bought a new one for $63 at MCL. A look at the schematics would confirm.
Oh, ah, I think 9eight6 is in China these days.... ;)

my friend moodsman. how you doing. please don't send me this pm anymore.

pm from moodyman yesterday "You better chill real quick or I'll sue you for slander/libel- look it up you little mouthy frog . In Canada calling someone sick and a stalker is grounds for a lawsuit. Your about 6 yrs old inside so shut your mouth before it costs you$$$$$$$$"

YOU are the stalker not me. see up post#26. yes sue me bwaaahahahahhaha

do you think calling someone little mouthy frog is 'nice' and easily forgivable behaviour? quote from you post#22 http://986forum.com/forums/362514-post22.html

see you soon my new moodsman friend

Takart, I believe Woodsman genuinely responded to another member's request. What ever he adds up please just let him do his thing - it's a free world. Therefore could I please ask you (asking politely) to use another channel if you have any differences. This thread is meant for Headlights retrofitting.

That would be very kind, (civil) and much appreciated.