Porsche Headlight Retrofit [from CAD, prototyping to finish)

[particlewave]

Simple, yet elegant solution Mitch! Love it!

Fred...sorry for the build delay. Finals at school and holiday prep has been killing my free time
Build starts in 6 hours!
Shouldn't take too long since most of the work is already done.

[Nine8Six]

Originally Posted by particlewave

Simple, yet elegant solution Mitch! Love it!

Fred...sorry for the build delay. Finals at school and holiday prep has been killing my free time
Build starts in 6 hours!
Shouldn't take too long since most of the work is already done.

Uh-oh. I was hoping you'd take your time.... sort of letting me think that my-kit-is-cool-looking for a few more weeks.

Seriously, I can't wait to see how the green devil eyes turns out. Knowing your skills and creativity, I believe you'll have a few more surprises as well

[clickman]

As usual it's not that easy for us Canadians. We need the daytime running lights. I get the feeling I'm the first one of us to try to do this. If not, the rest of you Canuckleheads, please let me know!!

[particlewave]

I have something in the works click
I don't have DRLs, but wanted some form of running light, so I'm doing something completely unique. Mock ups of the idea look pretty sweet!

Stay tuned

[clickman]

OK particle, you've got my attention!!

In the meantime, I'll get Fred working on my kit!

How does quasi gun metal grey sound on a Seal Grey Boxster, instead of the standard silver?

[PaulDash]

Here (in Poland) daytime running lights are required year-round. Most people just drive with their low beams on all the time.

How would your projectors work in a situation like that? Any overheating?

I have a set of clear lights that I have to polish up and was thinking of retrofitting your kit at the same time. I'm still not 100% clear on the procedure, though, so if you can please PM with the instructions.

[Nine8Six]

Originally Posted by PaulDash

Here (in Poland) daytime running lights are required year-round. Most people just drive with their low beams on all the time.

How would your projectors work in a situation like that? Any overheating?

I have a set of clear lights that I have to polish up and was thinking of retrofitting your kit at the same time. I'm still not 100% clear on the procedure, though, so if you can please PM with the instructions.

Nice! Greetings from Shanghai Paul

Changing the xenon bulbs regularly will be your main concern. The manufacturer of the xenon bulb I am including in the kit rates them @ 2,000hrs. That said if you use your car 2 hrs per day, you are likely to need a xenon bulb refresh every two years (according to the manufacturer). In your case, I'd say changing them annually and they should perform at peak efficiency all the time. A pair of H1 Xenon bulbs (35watts ) will cost you a huge $20 each year. Not a crisis!

Bear in mind the complete assembly is made of aerospace 6061 T6 grade aluminum. That type of aluminum conducts heat about 2000 times faster than plastic (PE). The heat generated from the xenon bulb is not a problem and dissipated across the bowl (cast aluminum), the skirt and the bezel evenly. The whole thing effectively acts as a massive heat sink. The assembly runs at 45°C(min) 55°C (max) @ 60min operation. In Fahrenheit that would be 113°F(min) 130°F (max).

Ballasts can sustain the heat they are rated at which is between -40°C ~ 105°C (or 220°F). I've toasted a pair overnight in a enclosed environment (4"X6"X2" toolbox) and picked them up in the morning @ 54°C (130°F). So those passes my quality standards and comply with what the manufacturer swears by. A bad quality ballast can, and will, go up to 80°C ~90°C (175~200).

Regarding the DIY steps required to get this done, please let me know what procedure(s) you are not clear on and I'll do my best to explain in details.

[Nine8Six]

Originally Posted by clickman

OK particle, you've got my attention!!

In the meantime, I'll get Fred working on my kit!

How does quasi gun metal grey sound on a Seal Grey Boxster, instead of the standard silver?

PM sent Norm. Incl gunmetal light grey color visual.... essentially the same as seal grey (very close if not a perfect match).

You get to make the hard decisions

[particlewave]

Sanding, sanding, sanding...

Those ridges in the bottom of the reflector are a PITA. 60 grit sandpaper speeds it up some, but I still wound up with 4 bloody knuckles.



Almost there.

[Jamesp]

My headlights stink. They are yellowed, burned, dead halogens. even after polishing the outside, which was a vast improvement, the best thing that can be said about them is "disappointing". This is a super interesting thread, and everyone posting on the thread knows whats going on. As an outsider looking in, can you tell me what the heck are your plans for the headlights your sanding? Oh yeah, sorry about the knuckles.

[MitchSF]

Originally Posted by Jamesp

My headlights stink. They are yellowed, burned, dead halogens. even after polishing the outside, which was a vast improvement, the best thing that can be said about them is "disappointing". This is a super interesting thread, and everyone posting on the thread knows whats going on. As an outsider looking in, can you tell me what the heck are your plans for the headlights your sanding? Oh yeah, sorry about the knuckles.

Probably best to read this thread from the beginning. There are many options and many ways to do this.

The lens in front of the reflector on one of my lights was cracked and yellowed, too. A previous owner installed one of the gold tipped high power bulbs. I think they are called Silverstar. They run much too hot for these lights. As particlewave mentioned, the lenses are not used with this conversion.

[mayerstrat]

Sorry for the delay in posting pictures everyone. There were some internal rumors about being internationally transferred that caused me to put to the car on hold for a few weeks.

The headlights have been in for 3-4 weeks now and they run great. The only downside is that it does effectively eliminate the high beams. I'll wash the car tomorrow and get some pictures up before it goes into the shop to get new speakers installed.

[Nine8Six]

Nice one guys, thanks x100! Really looking forward seeing your NEW boxsters' (frontend)

Mitch - funny you've noticed about the beam being identical if not better than factory xenon headlights. We've recently compared those high performance projectors (the same that you have) with the litronic on a 996 here to find out that they outperform those as well

And I still don't know why!!!

I fear to ask any more questions at the projector manufacturer here. I'm actually fearing that he'll rumble for another 45min about his angular data and otha R&D achievements RE 'elliptical' and 'improved optics' this & that. As much as I like learning new stuff, I won't get caught there again

I'm just so happy to hear it worked for you guys as well

John - I refund your shipping if you can shoot a link to the high resolution picture you'll take (of course DSLR, the one with the Zanzibar car under the Utah sunset shades). Not only I'll make it public and dirty, I want to print it out and keep it along a replica of your kit. It's plexi-glassed souvenir style mate.... all we do here is serious stuff lol

[particlewave]

Haha! Thanks, the knuckles are recovering.

I'm sanding the reflective chrome finish off of the reflectors because I'm going to paint them black. Paint doesn't stick real well to that shiny stuff
It looks pretty slick all black with these projectors installed (see pg 3-4 of this thread). I'm hoping to be done by tomorrow, but holiday prep may cut into the project. Definitely will be done by Sunday...

Are the outer lenses on your halogens ruined also? The inner lens can be ditched with this upgrade

[Jamesp]

Yeah, after 120K and years in the hot Texas sun they are pretty much fried, inside and out.

[MitchSF]

Lights are almost finished. Last night I put them on the car without lenses to check all functions, and to align the beams. As much as I thought they were adjusted correctly using the horizontal line on the projector bowl as a guide, they were noticeably out of adjustment. After setting the adjustment and tightening the nuts, I locked them in place with some Goop, which is a flexible adhesive that dries harder than silicone.

The large plastic trim and metal reflectors were painted with VHT high temperature ceramic black pearl paint. Other than the switching relay I described in a previous post, no other changes were made.

I used an LED in place of the small parking light bulb. It compliments the 6000k xenon bulbs much better than the Edison bulb and would probably make a nice driving light because the white light floods the reflector bowl, although I doubt that I will make wiring changes for that to function.

I did think about using angel eyes mounted to the front of the reflector bowl, but I decided against it. That would be the perfect place for them, but they would be impossible to service once the lens is glued in place and I don't think that's the look I want to go along with this very conservative design. By the way, the car is Arctic Silver.

The only work left to do is to blow out any remaining dust, glue the lenses, and then give them a light polish. I bought them used and both have very light scratches. Then I'll wax them and apply Lamin-X film.

The beam is amazing on these projectors, with a well-defined cutoff that is much better than the lights on our A5 and new X3.

[particlewave]

Almost there. Please ignore the mess...it's been a long week

A few finishing touches and time to close up
Btw, the last time I opened these headlights for the first projector install, I used way too much sealant and they were a huge PITA to open this time and I damaged the outer lip a bit near the fog lights on both units. Nothing that will show or affect the seal, but not pretty and I'm a little disappointed with myself

[particlewave]

And just for good measure, I added a single (very bright) multicolor LED to each shroud so that I can change the devil eye look once in a while or just enhance the neon green

They don't necessarily have to be on or even hooked up, but just in case I want them... They will be powered by the running/parking light circuit and hooked up to a relay so that they shut off when the headlights are on to preserve life (wouldn't be visible with headlights on anyway).

[Nine8Six]

Let me share some top secret development with you:

Meet the NEW & MIGHTY Nitestalkers High Performance Bi-Xenon Projectors (no panic, the brand name is pure fiction for the moment LOL)

A few asked whether it was possible to add Angel Eyes to the kit. Especially the dudes based in Japan. I have a friend there who is marketing those projectors at the moment and its doing rather good - as if I wasn't busy enough with real life!

Those Angel Eyes will finally come "Optional" with the kit. The standard model without angel eyes will remain the main product of course but like every other products, it's always good to have some options.

So there you go (we designed this a week or two ago). Pure coincidence. Enjoy!




How it works:


^ 2mm*4mm slots are CNC'ed into the bezel. 32x of them.


^ I've designed a compartment to isolate the light emitted from the LEDs. This will be filled with high temp silicon over the LED ring circuit board. We don't want this to pollute the lens color which is often pitch black, or clear viewed from an angle.


^ I simply use a "Pure White" circular LED board and install a matte finish acrylic filter (see in greenish) to push out a colorful glow (red, yellow, green, etc.....). The matte finish acrylic is to prevent the nasty artificial LED glares so they look clean and soft looking.


^ Those are the ring that I am getting manufactured in OD80mm (the internals only, we throw away the plastic casing). It will be a 32x led board powerd by a miniature/external controller (kept away from the heat). The board/LEDs will dissipate their heat at the Bezel's 6061 T6 aluminum so no heat built-up (unlike common plastics!). The Angel Eyes mini controller connects to the Parking Light's +/-. Easy!


^ Using the filter design/concept, not only it cleans off the glares, colors are also unlimited. We will offer those in PINK, VIOLET, ORANGE, BLACKLIGHT, etc etc ect

Like it?

[MitchSF]

Originally Posted by particlewave

And just for good measure, I added a single (very bright) multicolor LED to each shroud so that I can change the devil eye look once in a while or just enhance the neon green

Great idea! If the LED is bright enough to see during the day, maybe it would make a good angel eye alternative. My lights are sealed, otherwise I'd experiment with this, too.