Thứ Hai, 7 tháng 11, 2016

About to start new bugeye headlight project part 7

brcewane 09-01-2008 09:58 PM

*********** UPDATE ***********

Ok.. so I tore into these headlights today starting at noon... and went to dinner time and then followed up with about an hour and a half after our little girl went to bed.

Started with this once it was all taken apart...
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/headlights001.jpg[/IMG]

Here is a quick look of the BIG ASS shroud that I picked up for them:
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/headlights002.jpg[/IMG]
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/headlights003.jpg[/IMG]

Yes that is a drain cleanout :D The reason I went with it was so that I could mess around by molding the cap into the headlight unit and then screw on the shroud after I it was all done.

Here is an idea of where it will fit:
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/headlights004.jpg[/IMG]

Next I cut out a ton of the old fiberglass work. There was still a bit of trimming left to do after this point but you get the idea. I used the back of the old projector housing as my guide to make sure the new shroud and mounting point was pointing in the right direction.
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/headlights006.jpg[/IMG]

Now you can see what I mean by the shroud threading onto the base plate. The base is the cap from the drain cap... but I cut out all the inner material so that it was smooth all the way through.. that was lots of fun... NOT
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/headlights007.jpg[/IMG]
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/headlights008.jpg[/IMG]

And here you can see that the projector mounting plate mounts nicely to the back of the drain cap and will be screwed into place:
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/headlights009.jpg[/IMG]
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/headlights010.jpg[/IMG]
brcewane 09-01-2008 09:58 PM

Everything back together:
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/headlights011.jpg[/IMG]
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/headlights012.jpg[/IMG]
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/headlights013.jpg[/IMG]

So now I screwed the base plate onto the back of the old projector housing to hold it in place. And then threaded on the shroud. As you can see it doesn't have enough clearance to get the OEM lense back on:
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/headlights014.jpg[/IMG]

So I cut the width of a strip of tape off the end of the shroud and it all now fits:
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/headlights015.jpg[/IMG]
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/headlights016.jpg[/IMG]

So tonight I finished up modifying the other shroud (cut the excess of the end to fit) and also cut out and modified the cap to be straight through and mounted the bracket on the back.

This headlight is now ready for some fiberglass that I will have to pick up tomorrow. The other headlight now needs to come apart and get cut up to match.. the shroud is ready to go.

What I am hoping for is to get the other headlight cut up and all the fabric glued in place tomorrow night and ready for the resin.
GeoffSFAs10 09-01-2008 10:11 PM

looks interesting still. i'm gonna keep an eye on this one
cruzinWRX2 09-01-2008 10:45 PM

man i wish i had the patience and ideas that you have.
Handsdown 09-01-2008 10:54 PM

damn. higher is better for seeing with lights, so that will be cool.
kiwee 09-02-2008 09:35 AM

here we go!
kiwee 09-02-2008 09:37 AM

[QUOTE=brcewane;23540823]Hopefully all the hoses are staying put and there are no leaks yet :D[/QUOTE]

so far it survived a trip to work. 30km (~20m)
xdrian 09-02-2008 09:59 AM

always working hard on something new! i love it
wrxracer519 09-02-2008 11:11 AM

this is nuts, you guys with these light mods are amazing. cant wait to see the finished product
hella_sti 09-02-2008 04:40 PM

lots o work, damn!
obsnw 09-02-2008 05:39 PM

You've certainly created a monster here. I like to see this kind of ingenuity, reminds me of me. Even with having seen all your work, I still can't stomach the wallet drain of Jdm's. Just so you know, I will shortly be following in your footsteps, using your mistakes and successes to build the most righteous set of bug eyes ever... hopefully. Well maybe not, but I sure will try.
Superorb 09-03-2008 10:04 AM

Anything new? Awesome work man!

Will TSX projectors fit in the ebay knockoffs without much cutting? If not, is there any HID OEM projector that will fit?
budahrocket 09-03-2008 09:49 PM

Brce you should put some serious thought into talking to some chinese factory owners and having someone produce your design on a large scale. I'd imagine there's no reason why whoever makes the e-bay headlights couldn't make a new mold to match the ones you've been making. I will never understand why the cheap e-bay stuff doesn't copy the good mods. I know it would be lower quality than the real deal, but there's no reason it can't look like the real thing.
Handsdown 09-03-2008 10:41 PM

the car is too old and the lens cover would be too much money.


the ebay stuff did copy the good mods, they copied the wrc ones but with a larger and uglier turn signal. the production costs are MOSTly in making the mold and designing the optics around it. once you have the mold it's cheap to knock out a ton of them.

because most of the cost is in the design and initial costs, it's easier for them to just use the OEM ones or the wrc style ones they made back in 02.
brcewane 09-05-2008 07:12 AM

Well it looks like I won't have the headlights finished for Saturday... just too much time needed for resin to cure and finicky sanding.

I do have a bunch of pics of the progress so far.. I'll try and upload them soon.

[quote]Will TSX projectors fit in the ebay knockoffs without much cutting? If not, is there any HID OEM projector that will fit?[/quote]

I'm sure you could get some different projectors to fit... but it will involve some fabrication.. the back of the projector housing is bigger than 90mm, but it is configured to mount projectors from the front, not the back.

If you want to have a projector's mounting points at the back, you need to cut out the back of the housing like Handsdown did.
brcewane 09-06-2008 06:07 PM

*********** UPDATE *************

Here are some more progress pics... trying to get the resin to cure at night is proving to be a bit challenging... it is much easier when you can just pop them out into the sun.

Hopefully I will get some time tomorrow to work on them some more

[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/more002.jpg[/IMG]

[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/more003.jpg[/IMG]

Started laying in some of the curves on the front of the one headlight:
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/more004.jpg[/IMG]
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/more005.jpg[/IMG]

And I've been re-enforcing the rear of the headlight. To get the shapes I need, I have to lay some fiberglass down in different directions and then trim away the unwanted areas...
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/more006.jpg[/IMG]
claycron 09-06-2008 08:02 PM

I think there going to look excellent when finished kind of like a JDM/Morette look going on. Thumbs up
state 09-09-2008 06:08 PM

ummmmm, yea.... It's been more than 24 hours since your last update...

I'm gonna need you to keep me updated with more pictures every hour on the hour :lol:


keep up the good work!
brcewane 09-10-2008 08:36 AM

LOL.. I'm up on vacation at my parents place with my family for a good old fashion small town fall fair... once I get back I'll start back in on them :D
brcewane 09-15-2008 09:43 PM

Not a lot of updates on the headlights.. I've been spending the most of my time overhauling my garage and giving it the royal treatment of cabinets and tool chests :D

But here is a quick pic of some of the progress made:
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/additional.jpg[/IMG]
Noeladams 09-15-2008 09:44 PM

you do some really good work!!!!
FromEvoToRS37 09-16-2008 01:40 AM

Hey when you get them finished you should talk to cesar at lightwerks and team up
BeBop86 09-16-2008 06:52 AM

Turn signals?
brcewane 09-16-2008 09:12 AM

[QUOTE=BeBop86;23718682]Turn signals?[/QUOTE]
I removed the turn signals because I don't need them. My front bumper is a WRC bumper that has integrated turn signals.
[IMG]http://img.photobucket.com/albums/v671/brcewane/301244850_tMzZy-M.jpg[/IMG]
k20utah 09-16-2008 06:07 PM

WoW....Such a good lookin bugeye.....what grill is that?
skindog 09-16-2008 06:40 PM

read through most of this today. been thinking for a long time that someone, somewhere was doing a project with their headlights beyond the koji. i almost can't believe it. good job, can't wait for the final product.

Subscribed!!!
Handsdown 09-16-2008 07:20 PM

eugh!
[img]http://i35.tinypic.com/111juqr.gif[/img]
danscoobywagon 09-16-2008 08:12 PM

lol nice
Noeladams 09-16-2008 09:58 PM

thats cool... lol.
brcewane 09-16-2008 10:11 PM

[QUOTE=k20utah;23726282]WoW....Such a good lookin bugeye.....what grill is that?[/QUOTE]
The grill is all integrated as part of the bumper..
[IMG]http://img.photobucket.com/albums/v671/brcewane/widebody/fourstar/fourstar006-1.jpg[/IMG]
BeBop86 09-17-2008 03:22 AM

[quote=Handsdown;23727105]eugh!
[IMG]http://i35.tinypic.com/111juqr.gif[/IMG][/quote]

Looks like a robot goin crazy lol :lol:
skindog 09-17-2008 08:55 AM

[QUOTE=brcewane;23729203]The grill is all integrated as part of the bumper..
[IMG]http://img.photobucket.com/albums/v671/brcewane/widebody/fourstar/fourstar006-1.jpg[/IMG][/QUOTE]


Wow is right, that is a very nice piece!
subaru3169 09-17-2008 09:01 AM

[QUOTE=BeBop86;23731992]Looks like a robot goin crazy lol :lol:[/QUOTE]

watch out, wall-e!! :lol::lol:
WReXd 09-17-2008 11:05 AM

wth I remember you saying you don't have enough money for sti headlights, but you have a wrc bumper?!?! that was just an excuse to fabricate your own badass headlights, huh...
Superorb 09-17-2008 12:32 PM

[QUOTE=WReXd;23734388]wth I remember you saying you don't have enough money for sti headlights, but you have a wrc bumper?!?! that was just an excuse to fabricate your own badass headlights, huh...[/QUOTE]
Unless the Mrs. had some input...
brcewane 09-17-2008 12:46 PM

[QUOTE=WReXd;23734388]wth I remember you saying you don't have enough money for sti headlights, but you have a wrc bumper?!?! that was just an excuse to fabricate your own badass headlights, huh...[/QUOTE]
It's not that I don't have enough money for sti headlights.. I just can't justify putting $1000+ into getting a set where I would rather spend that kind of money elsewhere on the car.

This is my hobby to do this fiberglass work, so I find it fun and relaxing.
obsnw 09-17-2008 04:42 PM

well, if you don't wear a mask it is really relaxing, haha
Handsdown 09-20-2008 03:40 AM

you're gonna hate me...


but look what hella just rolled out.

[url]http://www.rallylights.com/hella/60mm_modules.asp[/url]
[img]http://www.focuztech.com/xcart/images/cache/8d070cb7babac19d8631d00a02012895.jpg[/img]
60mm. these will fit in the ebay tunnels. that, and they are 9005.

which means this:
[img]http://i24.ebayimg.com/03/i/02/4d/f9/07_12_s.JPG[/img]

:sadbanana: that these didn't show up sooner.
Superorb 09-20-2008 11:23 AM

^^ And they're even pretty cheap too, only $100 for the pair! How much work would be needed to get them into those ebay housings?
Koji 09-20-2008 01:19 PM

I'll let you know in about two months. I'll be partially replicating what brcewane and HandsDown have done (he has a seperate thread). Glad you found those handsdown - that'll help me out immensely.

Great work so far bruce - this thread and your work is the reason I went out and learned to fiberglass.

Cheers,
Koji
Handsdown 09-20-2008 04:02 PM

oh snap, now that two master craftsman are on the job my inabilities will be twice as obvious!

and because i haven't seen these new projector units in person i can't actually say for sure that the 60mm modules will fit in the tubes for mounting... they may require a similar mount to what i've done with my wrx projectors. but i know their projector and integrated shroud will fit in the housing tunnel.

it seems that the mounting holes have a maximum outside horizontal footprint of 3.75" inches. that may be a little too big.

here's a thread from a flat-cut-off version used in ATVs. you may have to register.
[url]http://www.hidplanet.com/forums/viewtopic.php?p=404921#404921[/url]

he's put a kit hid bulb in them and they seem pretty fool-proof in terms of glare above cutoff, even if they do have an increased gradient of light falloff from focus.
Superorb 09-20-2008 09:09 PM

Damm, those things are awesome, and they'd make excellent fog lamps for 04+ cars.
subaru3169 09-20-2008 11:24 PM

dayam, if i had more money, i'd get started on those ebay lights and hella modules
Handsdown 09-21-2008 03:46 AM

[QUOTE=Superorb;23777420]Damm, those things are awesome, and they'd make excellent fog lamps for 04+ cars.[/QUOTE]

actually lowbeams have too much depth, they're horrible for fog. you want something short flat and wide, like a hamburger patty from wendys. lowbeams are more like an upside down muffin top.

the extra depth on lowbeams puts too much light too close to the car when mounted low like fogs, and the centerweighted focus gives it too much intensity in the front. you want it flat to cut through the fog and even to only give you enough to see by at a very slow pace.

this flat, even beam causes the minimum amount of reflected kick-back light.

for lowbeams though, these should prove to be awesome.
brcewane 09-21-2008 08:34 PM

Nice find Handsdown... yes, If I had found these earlier, they would have simply been mounted in my existing headlights and I would have been set.. Grrr...

My Garage is still a mess, my mechanics toolchests were supposed to be here on Friday but still no word on them.. Hopefully I will get some time this week to do some more work on the headlights. The damn sun is setting much earlier now and I'll need some good lighting soon :D
EnterTheDragon 09-21-2008 09:03 PM

scribes
naggg 09-21-2008 09:57 PM

SUBSCRIBED! amazing work!
MMWRX 09-23-2008 03:10 PM

This makes me wanna spend more time in the garage, this is amazing. keep up the bad ass diy
nixgame22 09-30-2008 04:55 PM

any updates?
big16gwrx 09-30-2008 05:11 PM

thats alot of work you have in those lights... looks good...
brcewane 09-30-2008 08:49 PM

I did a bit more work on the headlights this weekend... kind of split my time between getting all my tools put away in my new tool chests, fabricating a bracket for the distribution block for my new fuel rails, working a bit on my new gauge pod and some work on the headlights.

So I was starting to look at the headlights a bit more and realized that the cup under the new larger projector was too harsh and throwing off the lines of the headlights. So I put in some new material to make a better shape:
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/more007.jpg[/IMG]

I also added some more material to the second headlight to start to shape it. I am using the first headlight as a bit of a guinea pig and then following what works on the second one. Then I laid down some resin into the fabric:
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/more008.jpg[/IMG]

Then after some sanding and some more body filler I was able to smooth out some more of the shape under the larger projector. This picture is with the larger projector shroud laying in place as well:
[IMG]http://img.photobucket.com/albums/v671/brcewane/hybrid/headlights/more009.jpg[/IMG]
Superorb 09-30-2008 09:31 PM

Keep it up!
nixgame22 10-10-2008 01:15 PM

updates.....we demand them :devil:
rotorhead24 10-19-2008 02:10 PM

i want these NOW! anybody know where else to find them? (they are not listed on that site anymore):furious:[quote=Handsdown;23771886]you're gonna hate me...


but look what hella just rolled out.

[URL]http://www.rallylights.com/hella/60mm_modules.asp[/URL]
[IMG]http://www.focuztech.com/xcart/images/cache/8d070cb7babac19d8631d00a02012895.jpg[/IMG]
60mm. these will fit in the ebay tunnels. that, and they are 9005.

which means this:
[IMG]http://i24.ebayimg.com/03/i/02/4d/f9/07_12_s.JPG[/IMG]

:sadbanana: that these didn't show up sooner.[/quote]
rotorhead24 10-19-2008 02:44 PM

i did some more searching and found them here...
[url]http://www.focuztech.com/xcart/product/60mm-Hella-Projector-assembly-low-beam.html[/url]
MOBBiN 10-19-2008 03:20 PM

any updates?
brcewane 10-20-2008 11:11 AM

No updates right now... been busy getting ready to come down to California.. I'm in Santa Clara for the week helping put on the BlackBerry Developer Conference
Handsdown 10-20-2008 01:31 PM

awesome! i want a blackberry.:lol:
brcewane 10-21-2008 10:06 AM

[QUOTE=Handsdown;24144775]awesome! i want a blackberry.:lol:[/QUOTE]
LOL... well there is an entire convention center full of them down here right now.. about 800+ people all carrying one...
MNsuby 10-21-2008 12:34 PM

updates

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