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986 Forum - The Community for Porsche Boxster & Cayman Owners (http://986forum.com/forums/index.php)
-   DIY Project Guides (http://986forum.com/forums/forumdisplay.php?f=50)
-   -   Porsche Headlight Retrofit [from CAD, prototyping to finish) (http://986forum.com/forums/showthread.php?t=48169)

particlewave 06-14-2014 07:47 PM
Quote:
Originally Posted by BFeller (Post 405601)
I purchased a used set of headlights. I opened the backs of the lights because they were rattling and found that each light had an HID kit installed. The rattling came from ballasts which were lose inside cover that seals the access to the bulbs. It looked like the weight of the ballasts had knocked the light buckets off the pivot ball. Also the seal on one light was mush. Thursday was spent polishing the yellowed and gunk-ed up lenses. They now are looking like brand new.

Today I used Particlewave's video to open both headlights. I baked the first one for 15 minutes with no give on the silicone. It went back into the oven for another 10 minutes since it had cooled a bit. It came apart easy enough the after the second bake. The second one went in for 20 minutes and came apart quickly. It was then easy to pop both of the headlight bucket assemblies back onto their pivot balls. The internal lens covers came off with only one plastic tab having broken. Once the internal light covers were off there was dust or dirt around the reflectors. It looked like residue from a bulb burning off moisture.

Next step have to be ordering the new projector lights.
Excellent work!
Those ball joints cause me more headache...

particlewave 06-14-2014 07:49 PM
Quote:
Originally Posted by tightbox (Post 405628)
Make sure to spray a permanent protective UV coating on the newly polished lenses, or they will be cloudy again in no time!
Absolutely! Followed by a light polish, they will shine like new! :D

Now, if only something could be done about the darn internal crazing of the lens... :(

tightbox 06-15-2014 03:33 AM
Particle - what UV spray do you use? I purchased some clears that were a bit rougher than represented in the sales description, so I'm still in the research phase currently.

particlewave 06-15-2014 06:17 PM
To be honest, I'm pretty new to the whole restoration thing. I only did a couple of sets for members here because they were so bad that I couldn't make them any worse.

That said, Optimum Opti-lens is some pretty awesome stuff, but not a spray and pricey.
What have you tried?

tightbox 06-17-2014 05:34 AM
Haven't tried it yet, just received some lenses that were in worse shape than I would have liked, and have been researching what to do (other than mail them back to the seller!).

Wonder if I could use a regular UV stable automotive clear coat from paint scratch.com?

Nine8Six 06-17-2014 05:55 AM
Quote:
Originally Posted by tightbox (Post 406008)
Haven't tried it yet, just received some lenses that were in worse shape than I would have liked, and have been researching what to do (other than mail them back to the seller!).

Wonder if I could use a regular UV stable automotive clear coat from paint scratch.com?
Mine were original lenses and they received no special care for ten+ years and had some minor scratches so they had to be wet sanded at some stage. Although NOT recommended by any pro it worked for me. I didn't used UV protect whatsoever BUT I have to regularly polish them when I do the 986's quarterly detailing. Edit: takes 10min per headlight

I'm just saying this because the lenses looks as new as the day I restored them 36+ months ago. Guessing if you maintain them regularly it shouldn't be any different for yours.

Been using Meguiar's Plast-X Clear Plastic Cleaner. Could well have UV protect additives dunno... rarely read labels ;) These polish products are all the same thing really (de-oxidizers + ultrafine abrasive particles)

BFeller 06-17-2014 04:01 PM
I think the Turtle Wax or Mequire's headlight kit comes with a UV protectant for the plastic. A wipe on treatment that seems to be one that gets repeated like waxing.

particlewave 06-24-2014 01:46 PM
FYI - For readers interested in the retrofit, I am booked full through August 15.

Kits are still available for DIYers ;)

MitchSF 06-25-2014 03:02 AM
Another option is to use Lamin-X. The thick, clear headlight film does a good job of hiding small scratches.

Crono0001 06-26-2014 01:41 AM
Particlewave

Am I included in the "before August 15th" group?
My projectors should be reaching you Monday!!

particlewave 06-26-2014 01:56 AM
Quote:
Originally Posted by Crono0001 (Post 407327)
Particlewave

Am I included in the "before August 15th" group?
My projectors should be reaching you Monday!!
Absolutely! Got you penciled in ;)

BruceH 06-28-2014 11:27 AM
Finally got mine installed thanks to the outstanding work of Charles and Fred!:cheers: I have to say that both of these guys are fantastic guys to work with. We had some UPS issues which caused quite a bit of damage but Charles was able to repair everything to better than new, thanks again for all of your hard work and contributions to this forum!

http://986forum.com/forums/uploads01...1403983486.jpg

http://986forum.com/forums/uploads01...1403983506.jpg

http://986forum.com/forums/uploads01...1403983539.jpg

http://986forum.com/forums/uploads01...1403983586.jpg

particlewave 06-28-2014 02:23 PM
I'm just glad that ups didn't play soccer with them this time :D

They look really nice on your car, Bruce! The chrome reflector and bare shroud make the whole setup look very OEM, yet unique at the same time...like some kind of rare, never released Litronics.
Loving it! :cool:

BruceH 06-28-2014 02:58 PM
Quote:
Originally Posted by particlewave (Post 407783)
I'm just glad that ups didn't play soccer with them this time :D

They look really nice on your car, Bruce! The chrome reflector and bare shroud make the whole setup look very OEM, yet unique at the same time...like some kind of rare, never released Litronics.
Loving it! :cool:
I agree and that was what I was aiming for, un upgraded OEM look. Turned out perfect thanks to you:cheers:

eicheldp 06-28-2014 06:09 PM
Quote:
Originally Posted by BruceH (Post 407790)
I agree and that was what I was aiming for, un upgraded OEM look. Turned out perfect thanks to you:cheers:
Bruce,
They look great! Now I got to see what my Lapis Blue 04S will look like. Just pulled the trigger with Fred for the gun metal grey w/ White Angel eyes and leaving the rest of the headlamp unpainted.

@Charles - I'll be in contact soon to arrange for a winter time install. :D

Nine8Six 06-28-2014 09:35 PM
Quote:
Originally Posted by BruceH (Post 407749)
Finally got mine installed thanks to the outstanding work of Charles and Fred!:cheers: I have to say that both of these guys are fantastic guys to work with. We had some UPS issues which caused quite a bit of damage but Charles was able to repair everything to better than new, thanks again for all of your hard work and contributions to this forum!

http://986forum.com/forums/uploads01...1403983486.jpg
Oh cool Bruce!!! Looking good.

and what's that blue reflect on the above pic? A Charles' special devil eye effect, LED, how did you guys managed that?

Nine8Six 06-28-2014 09:44 PM
Quote:
Originally Posted by particlewave (Post 407077)
FYI - For readers interested in the retrofit, I am booked full through August 15.

Kits are still available for DIYers ;)
They are available yes but I am one week late in getting them out now. Trying my best to catch up with time but with 18 orders/kits on the backburner atm, its pretty damn hard to meet up my 1(one) week mfg-time promise :/

Kits shipping this coming Tuesday for Fergus, Simon and Ed. Next batch sends out this coming weekend.

Your customer's kits are being mfg this coming week Charles, shipping beg of next week.

Nine8Six 06-28-2014 09:46 PM
Quote:
Originally Posted by eicheldp (Post 407816)
Bruce,
They look great! Now I got to see what my Lapis Blue 04S will look like. Just pulled the trigger with Fred for the gun metal grey w/ White Angel eyes and leaving the rest of the headlamp unpainted.

@Charles - I'll be in contact soon to arrange for a winter time install. :D
Got ya in for this week Don. Special projectors for special people only :)

Thx btw mate, email received

Nine8Six 06-28-2014 10:34 PM
I like this. Crazy huh

http://986forum.com/forums/uploads01...1404023339.jpg

Van914 06-29-2014 04:37 AM
Fred & Charles,
This has to be one of the best Mods for our cars. I want to thank you for taking the time and effort.
I love mine.
The New styling is fantastic!


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