Porsche Headlight Retrofit [from CAD, prototyping to finish)

[amagalla]

BTW...do you happen to have the "flash to pass" relay diagram?

Tony

[PaulE]

Originally Posted by amagalla

BTW...do you happen to have the "flash to pass" relay diagram?

Tony

These are the flash to pass relay diagrams. They are somewhere in the 81 pages of this thread but I happened to have saved it. I was in the same boat as you with the Angel Eyes last year. They start to burn out and flicker. They are epoxied into the inside of the shroud, and looked impossible to get out without ruining the shroud, so I just deactivated them by cutting the wires to them and reactivating my parking lights. You will see what I mean when you take yours apart.

I also had to re-glue one of the lenses in my projectors. I found that a clean, empty Progresso soup can was the perfect diameter for resting the shroud in face down after carefully gluing in the lens so that it could cure with the lens in the correct position.

For the cracked and falling off insulation, I found that clear flexible heat shrink tubing and heat shrink butt connectors with solder and new sections of wire did the trick for me on a spare set of headlights I built up over last winter. Good luck!

[particlewave]

Originally Posted by amagalla

Well, if I have to take that stupid thing apart to reattach the lens, I might as well fix the AE at the same time. My real problem now is looking at the factory wiring, all the jacket is peeling away from the wire on the original wiring. I think I'm going to have to rewire the factory plugs. What a pain.

Tony

IIRC, the LED AE ring is epoxied in, as well. It shouldn't be too hard to dig (dremel?) it out, though.

Originally Posted by amagalla

BTW...do you happen to have the "flash to pass" relay diagram?

Tony

The diagrams Paul posted are not quite right...the first one is to turn the AE's off when headlights are on and the second was for a more specific application.
This is the flash to pass relay diagram if you have original halogen high bulbs:



Also, to remove the nut, try some heat. Get a small butane torch and heat the post so you don't damage the reflector bowl. Careful, now...

[PaulE]

Originally Posted by particlewave

The diagrams Paul posted are not quite right...the first one is to turn the AE's off when headlights are on and the second was for a more specific application.
This is the flash to pass relay diagram if you have original halogen high bulbs:

A little knowledge is a dangerous thing, sorry!

[amagalla]

Originally Posted by particlewave

IIRC, the LED AE ring is epoxied in, as well. It shouldn't be too hard to dig (dremel?) it out, though.

The AE on mine wasn't epoxied in. It was held in by the black retainer ring, which was epoxied to the lens that was epoxied to the aluminum base. The black ring and the lens were no longer epoxied so everything came out with no issues. We'll have to wait an see if the other one is like that too.

Originally Posted by particlewave

Also, to remove the nut, try some heat. Get a small butane torch and heat the post so you don't damage the reflector bowl. Careful, now...

I used wd40 and a heat gun, I got it to the point where the WD40 was smoking, and still no go. What I'm going to do is unscrew the assembly (with the lens, AE, and the high beam iris) off the post and leave the post in there.

Tony