Thứ Hai, 7 tháng 11, 2016

About to start new bugeye headlight project part 1

brcewane 03-16-2006 08:46 AM

About to start new bugeye headlight project
Well I've started to acumulate all the parts that I need for my custom headlight project that I am about to embark on. I'm going to make sure that I update this thread with the progress that I make so if anyone else feels adventurous they can join in the fun on their own.

So far I have the following:
- Spare Bugeye headlight lense cover
- Spare Bugeye amber headlight turn signal cover
- Cheap $199 halo projector headlights from ebay..

Generally the final project will be a combination of these different styles:
[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/ebayphoto.jpg[/IMG]
[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/headlight1.jpg[/IMG]
[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/sti_jdmprojector02bg.jpg[/IMG]

As you can see these ebay lights will allow for the stock Bugeye lenses to fit over top of them to give the STi look.. however the the top area is for the signal light area much like the Koji/painted stock headlight mod.

So basically I am going to modify the 2 projector cylinders to seem more like the STi headlights instead of the WRC type of headlight.. so you will see the cylinder tubes for the projectors much like the STi lights.

As you can see, the cylinders are there on the ebay lights, it is just a matter of exposing them and molding them with the rest of the headlight to give it more of a 3D interior like the STi light:
[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/back.jpg[/IMG]

I will be removing the IMO cheesy white/clear cover on the ebay lights, mold over the holes left by them and glueing the stock Bugeye amber signal cover over the turn signal. Also modifying that area a bit more to flow with the molding being done on the projectors.

At the end I think I will paint them a gunmetal with metalic fleck so they look black from a distance, but gunmetal up close. Also paint the inside of the projector cylinders with chrome paint and hook up the halo's to the parking lights.

It should be an interesting project carving up these lights...

To be continued....

Tim
brcewane 03-16-2006 08:57 AM

Well I now have all the parts that I need and I have started the process.. I have posted up some pics of the headlight unit and its parts plus some of the first cuts so you can kind of get the idea of where I am heading with it.

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

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

[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/back2.jpg[/IMG]

[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/back1.jpg[/IMG]

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

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

[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/light1.jpg[/IMG]

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

[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/cut1.jpg[/IMG]

[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/cut2.jpg[/IMG]
Hank3 03-16-2006 09:59 AM

Cool - hope it works out for ya. In anycase, kudos for trying something new. Are you going to at least retro some quality projector units into the lights?
brcewane 03-16-2006 10:04 AM

Don't know about retro fitting some other projectors in there or not yet.. going to see what the light output is with some Xenon bulbs or silverstars...

Might end up putting in a HID kit into them.
bahboy20 03-16-2006 10:08 AM

projectors
what brand projectors came with the lights, not valeo are they?

dan
brcewane 03-16-2006 10:50 AM

[QUOTE=bahboy20]what brand projectors came with the lights, not valeo are they?

dan[/QUOTE]
no idea.. haven't really even looked at them closely yet
ptirmal 03-16-2006 12:26 PM

good luck, keep us updated... I would paint the black another black, maybe something more glossy, it looks kinda dull how it is now
Mulder 03-16-2006 12:31 PM

If you aren't going to replace the lighting units themselves, you will end up with a set of nice-looking lights with horrible lighting performance. The beam pattern of those projectors has been reported to be awful, and the reflectors are just as bad.
IMO this is only worth doing if you retrofit some quality lighting modules. And whatever you do, please do not put HIDs in those things, it will only make the situation far worse.
ptirmal 03-16-2006 01:44 PM

yea dont put a kit in without real hid projectors... I havent seen the halogen performance first hand but it's supposed to be worst than stock, a worthy upgrade would be at least replace the projectors (low beam) with halogen projectors off ebay (oem from a decent car, audi saab, etc) or hidplanet (fog projectors)... itll produce a decent beam for low beam projectors
Hank3 03-16-2006 02:09 PM

[QUOTE=Mulder]If you aren't going to replace the lighting units themselves, you will end up with a set of nice-looking lights with horrible lighting performance. The beam pattern of those projectors has been reported to be awful, and the reflectors are just as bad.
IMO this is only worth doing if you retrofit some quality lighting modules. And whatever you do, please do not put HIDs in those things, it will only make the situation far worse.[/QUOTE]
I was trying to take the subtle approach ;)
eurospek 03-16-2006 02:54 PM

[img]http://img.photobucket.com/albums/v671/brcewane/headlights/sti_jdmprojector02bg.jpg[/img]

Nothing will ever top the hotness of the original, there is just no way!
brcewane 03-16-2006 03:18 PM

^^ you are right... but this is better than a kick in the nuts from my wife if I spend $1000 US on the STi projectors
abosworth 03-16-2006 03:22 PM

[QUOTE=brcewane]^^ you are right... but this is better than a kick in the nuts from my wife if I spend $1000 US on the STi projectors[/QUOTE]

:lol:
TygerStile 03-16-2006 03:30 PM

good luck with the project.
Psipwrd 03-20-2006 05:31 AM

susbcribed
Lexington 03-20-2006 11:31 AM

I did something similar to this...

I took hella 90mm projector modules and grafted them into the ebay lights, then I painted the whole housing to match.

I liked it, had great light output, but I just like the look of the JDMs better.
Handsdown 03-20-2006 11:36 AM

yeah, for 120 bucks said and done, the hella H9 projectors are beyond 'worth it'.

they put out 2100 lumens with the same life as normal bulbs, and the hella projector's optics are industry standard. the projectors you have currently have TERRIBLE beam patterns, if you do a side by side comparison you can see how bad the beams are. i remember seeing a picture of it but can't find it now.

this looks promising, but you'd be a fool to spend the 200+ DIY materials and the hours and hours of time without spending the extra 120 to get GOOD lighting out of it.
KAX 03-20-2006 12:28 PM

make sure you do a better job sealing it then this guy

[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/headlight1.jpg[/IMG]

otherwise, your efforts wont be worth it.

and ditto on the changing projectors to HID based with real HIDs.
Sylon 03-20-2006 12:31 PM

Wow, halo's in a bugeye, good luck with that! I'm no electrician, I would be bound to mess something up, good luck, I wanna see how that turns out!
imprezive one 03-20-2006 12:42 PM

I like your vision, interested to see how this turns out.
brcewane 03-20-2006 01:17 PM

Yeah.. I'm looking into those hella projectors.. maybe move the angel eye from the ebay ones to the hella one :D

I've found a few sites that sell them.. does anyone have a place with good prices that they have done business with??
brcewane 03-20-2006 01:41 PM

[QUOTE=Lexington]I did something similar to this...

I took hella 90mm projector modules and grafted them into the ebay lights, then I painted the whole housing to match.

I liked it, had great light output, but I just like the look of the JDMs better.[/QUOTE]
got any pics?
brcewane 03-20-2006 01:57 PM

Did a little bit more cutting this weekend... It is still freaking cold outside so the fingers can only take so much.

I have to do some more trimming of the upper area around the turn signal and then I should be able to fiberglass in the top. Need to do that first so that I have the support to cut out the area below the projectors marked in the green tape.

I'll be trimming down the cylinder on the outside that holds the projector to give a more staggered look like the JDM headlights as well. Just need that fiberglass work first to hold them in place.

[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/morecutting.jpg[/IMG]
[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/morecutting2.jpg[/IMG]
Enriched 03-20-2006 07:22 PM

very interesting definetly subscribed
hikeeba 03-20-2006 10:37 PM

Very interesting. I can't wait to see more progress. 10 for originality.
Jackie 03-20-2006 11:50 PM

You know, if someone were to make JDM replica headlights, they'd make an absolute fortune. I don't think there's a bugeye owner who doesn't want JDM's, but doesn't want to spend $1k on them.
Handsdown 03-21-2006 01:13 AM

[QUOTE=brcewane]Yeah.. I'm looking into those hella projectors.. maybe move the angel eye from the ebay ones to the hella one :D

I've found a few sites that sell them.. does anyone have a place with good prices that they have done business with??[/QUOTE]

rallylights.com are VERY helpful guys and they carry the full line of hella lighting products. super fast shipping and great service. i'd talk to them!
tw1zt1d 03-21-2006 02:09 AM

definitely interested to see how they turn out +1 for trying something different out
Uncle Ben 03-21-2006 02:56 PM

Very cool! I will keep checking back.
brcewane 03-21-2006 06:30 PM

I've been looking around to try and find something to easily retrofit my amber turn signal cover into these headlights. The mounting hole that is supplied on the ebay lights is too small to fit the amber cover into..

So I was looking around the house to see what I could find.. ends up that I found the perfect snug fit in a PVC coupler from some plumbing work that I was doing. I won't end up using this one, but will get a butt-joint coupler that is longer to provide a spot to use my amber cover.

[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/pvc2.jpg[/IMG]
[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/pvc1.jpg[/IMG]

I will cut out the existing bulb holder and graft the bulb holder part of it onto the back of my PVC and then blend the pvc into the headlight so that it is angled the same as the projector cylinders. When I am done you really won't even see the pvc it will be blended in behind the scenes.

[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/retrosignal.jpg[/IMG]
azimiut 03-21-2006 08:19 PM

[QUOTE=KAX]make sure you do a better job sealing it then this guy

[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/headlight1.jpg[/IMG]

otherwise, your efforts wont be worth it.

and ditto on the changing projectors to HID based with real HIDs.[/QUOTE]


Those are my headlights....
That was my first attempt. after messing with them several times, I finally got it right, using prjectors with HIDs from an Audi. gotta go find the pics somewhere.

what you see in the pic is not the seal of the headlights. they are sealed completely. the white there is from cutting the plastic. in order to get the lens over the housing you have to cut the lens like a clamshell with no edge. its hard to discribe without it right in front of you. you have to sand the plastic down where you cut so that it does not leave cutting marks. then I took a black sharpie and colored any part that was still white. after that just use RTV sealant, black of corse.

the headlights in the picture you have used just the reflector lights. since I have a good supply of HID projectors available to me(dont ask for any, sorry) cause I work at a high end bodyshop with lots of european cars, I got two cracked Audi TT lights. I took the HID equipment out, and when I saw how easy the projectors fit I tried it and it worked great. the only problems I had was that the lenses after rebuiding and updating several times, they had become scratched and with the projectors it really showed how bad they were. Also, the HID units themselves are mounted inside a sealed headlight unit in the Audi. in my car I could not do that and water became a problem. since then I have taken them out and replaced them with some black headlights because the plastic had become so scratched that no amount of plastic buff could make it better. they were getting hazy, even in the pic above they were not clear.

my most recent pictures I have of the headlights are these guys. some without the plastic lens and some with.

[IMG]http://www.modmycar.net/images/_MG_3316small.jpg[/IMG]

[IMG]http://modmycar.net/images/headlight.gif[/IMG]

I need to look around a bit more to find more pics
Handsdown 03-21-2006 08:22 PM

looks great, but i agree that sealing will be a problem with HID... which is why, at 2100 lumens, the halogen H9 projectors look like the best option to me.
brcewane 03-21-2006 08:44 PM

[QUOTE=Handsdown]looks great, but i agree that sealing will be a problem with HID... which is why, at 2100 lumens, the halogen H9 projectors look like the best option to me.[/QUOTE]
agreed.. that is most likely the route I will be going.... [b]azimiut[/b] your headlights were the inspiration for my little project...

Who knows.. if they turn out well, I might look into manufacturing them :D
Handsdown 03-21-2006 09:07 PM

i think it would be easier to manufacture than the current ebay ones and if you use good optics, they'd be better headlights for a fraction of the cost of morettes.
elsanto 03-22-2006 09:59 AM

definitely paint th black plastic to be black chrome like the HID versions.. so hot, I like this idea as im DIY till death, true it will probably end up costing as much as a used set of jdm's but they are your creation and have halos! hell yeah. are you going to paint the light column chrome like the v7's?
brcewane 03-22-2006 02:48 PM

[QUOTE=elsanto]definitely paint th black plastic to be black chrome like the HID versions.. so hot, I like this idea as im DIY till death, true it will probably end up costing as much as a used set of jdm's but they are your creation and have halos! hell yeah. are you going to paint the light column chrome like the v7's?[/QUOTE]
Yes, the light column will be chrome on the inside... and I am looking to paint them the blackchrome... kind of a gunmetal with a fleck in there
bahboy20 03-22-2006 06:38 PM

[QUOTE=Handsdown]i think it would be easier to manufacture than the current ebay ones and if you use good optics, they'd be better headlights for a fraction of the cost of morettes.[/QUOTE]

not quite sure what you meant by this? you can get morettes for much cheaper than jdms/edms. I got my morettes for 300 shipped i think...or was it 320. Thats pretty cheap. If you can build projector headlights for a 'fraction' of that cost, I think you could make a boatload of money.

I like the DIY aspect though, and await this outcome, so far it looks promising.

dan
azimiut 03-22-2006 10:00 PM

glad i was there to give you an idea. I did not have the patience to try them one more time. so they are sitting on my shelf in the garage waiting for another day to come to re-asemble them a different way. but now i have 3 pairs of HID projectors sitting on my floor, I wonder how I can fit them all in there......

I got it! HID turn signals!
J/K. good luck and be careful with the plastic. I should have worn gloves when I was working with them.

PS. the big advantage of using the factory plastic is that it still says subaru on it. FYI.
Handsdown 03-22-2006 10:08 PM

[QUOTE=bahboy20]not quite sure what you meant by this? you can get morettes for much cheaper than jdms/edms. I got my morettes for 300 shipped i think...or was it 320. Thats pretty cheap. If you can build projector headlights for a 'fraction' of that cost, I think you could make a boatload of money.

I like the DIY aspect though, and await this outcome, so far it looks promising.

dan[/QUOTE]
where? morettes have always been 600 everywhere i've seen... 450 on clearence...
i was thinking around 300 would be enough for some hella optics in a similar housing, that's all.
turbokonejo 03-23-2006 12:27 AM

I think these lights are going to turn out nice. The cutting you have done to the black plastic almost all ready looks like the jdm backing. Good luck with the DIY project.
brcewane 03-23-2006 08:26 AM

[QUOTE=azimiut]glad i was there to give you an idea. I did not have the patience to try them one more time. so they are sitting on my shelf in the garage waiting for another day to come to re-asemble them a different way. but now i have 3 pairs of HID projectors sitting on my floor, I wonder how I can fit them all in there......

I got it! HID turn signals!
J/K. good luck and be careful with the plastic. I should have worn gloves when I was working with them.

PS. the big advantage of using the factory plastic is that it still says subaru on it. FYI.[/QUOTE]
I noticed that you put the projectors in the inside cylinder... I wonder which location would be the best for the lowbeam projectors.. the inside or the outside??
azimiut 03-23-2006 08:28 PM

my problem was the length of the projectors. it depends on how long. since the ones I have put the coil right on the bulb, it made them pretty long and I could not mount them on the outside where I wanted them. so I put them on the inside. I dont think it really makes a big deal, its all on the best way you can make it to be how you want it.

my own sentence confuses me. I think i will go have a drink....
Psipwrd 03-24-2006 08:13 PM

Clarification
I thought about getting the ebay projectors (for the look) and I read the light output sucks. I figured HIDs would solve this prob so I have a few questions...

Has anyone actually used HIDs with the ebay projectors?

Is the ebay projector quality too crappy to fit an HID kit and see what the light output looks like? (pics?)

Is the ebay projector worth taking apart and resealing if the seal is the problem?

Just wanted to clarify before buying the ebay projectors and trying HIDs.
Mulder 03-24-2006 08:19 PM

HIDs will not solve the problem, they will only make it worse. These lights are indeed too crappy to use on your car.
natoli4 03-25-2006 12:54 AM

this is what mine look like...picked them up from an friend.

[url]http://hidtech.com/projects/DSC00760.JPG[/url]


Then I did the kogi and smoothed out the reflector area...

Half way down the page.
[url]http://forums.nasioc.com/forums/showthread.php?t=952056&page=4&pp=25[/url]

Now I have both high and low beam HID's!!! Even better than the JDM's!

Maybe HIDtech can get you the lights your looking for? :banana:
s204ownerEXTREME 03-25-2006 01:43 AM

dat one wif da carbon fiber look good
s204ownerEXTREME 03-25-2006 01:43 AM

yea i like it a lot
brcewane 03-26-2006 12:10 PM

Did a little more work on the headlights.. got the one ready for fiberglass.. now I just have to cut the other one to match. I fabricated my amber bulb cover holder to go into the headlight.

First I chopped the hole a little bigger:
[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/expandhole.jpg[/IMG]

Then I trimmed down the PVC coupler so that it would fit nicely behind the headlight. I also cut away the bulb holder and krazy glued it into the end of the coupler:
[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/bulbholder.jpg[/IMG]

Here are a couple of photos of what it looks like in the headlight. The angle is the same as the cylinders of the projectors. It will eventually be all molded in so you won't see the gap around them:
[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/holderside.jpg[/IMG]
[IMG]http://img.photobucket.com/albums/v671/brcewane/headlights/holderfront.jpg[/IMG]
Handsdown 03-27-2006 10:35 PM

looking better and better! if it were me, i'd fiberglass the empty spots, paint the recesses chrome and call it soup:lol:


on a serious note:

[i]How are you going to deal with heat dissapation?[/i]

I've heard these lights have trouble melting from the heat of 55w bulbs as it is, if you put a big windscreen on the front(OEM plastic cover) i can only imagine it getting hotter... any ideas? anybody?
natoli4 03-28-2006 12:44 AM

i'd say fiberglass where you need to and resin everthing else...sand it an then drill very small holes where no one can see it top and bottom to vent the heat. BTW, boy do you have a project on your hands. It took me probably a week to do mine without wiring, you got two weeks at least I'd say.
brcewane 03-28-2006 06:59 AM

I can drill a bunch of holes around the the cylinders where no one will see... kind of like a perferated pattern.

but just a question on that one.. will I not get lots of condensation on the lenses if the headlight is vented??

I will be using a fine sanding body filler that worked well on my other projects instead of resin.. resin just dries way too hard for fine sanding areas.

I just have to wait for some warmer weather to do the fiberglass work so that the resin will harden. Don't want to do the work in my garage because it stinks up the entire house.
elsanto 03-28-2006 04:44 PM

I wouldnt put holes to vent.. condensation in headlights SUCKS.. when i opened my JDM HID's the ballasts are internal. either they dont get that hot, or the heat isnt an issue.. i wouldnt sweat it (pun intended)
natoli4 03-28-2006 07:59 PM

I'd agree but I think he's putting lights in that are sealed unto themselves...correct? so venting shouldn't hurt..I dont think your going to melt anything anyway. Plastic starts melting somewhere in the 200-250 range.
Koji 03-28-2006 10:13 PM

Subscribes. :D Glad to see other people are still modding the bugeye lights. I haven't seen the HID Tech ones before, I may have to check those out.
twizzstyle 03-28-2006 10:30 PM

[QUOTE=brcewane]I just have to wait for some warmer weather to do the fiberglass work so that the resin will harden. Don't want to do the work in my garage because it stinks up the entire house.[/QUOTE]

Are you using polyester resin? That stuff stinks like ass and doesn't work all that great. Many epoxy resins will have virtually NO smell to them at all.
azimiut 03-28-2006 11:30 PM

For the heat, there was no problem I let the lights run for a long time just to see how hot they would get, dont worry. when I attached the mounts from the projector, i used several types of glue, epoxy what not. I tried epoxy, they type of material it was made out of did not except the epoxy very well. then I tried some ABS Weld-on Brand pipe glue. worked Very well. then they were broke when I put the new engine in.

so at this time I began working at a body shop and I used some 2 part stuff called panel bonding made by 3M. it will glue anything to anything.

just make sure that you prep the plastic really well.
brcewane 03-29-2006 07:27 AM

[QUOTE=twizzstyle]Are you using polyester resin? That stuff stinks like ass and doesn't work all that great. Many epoxy resins will have virtually NO smell to them at all.[/QUOTE]
Yeah, I've been using polyester resin... might look into some epoxy resins
Jsunn 03-29-2006 08:37 AM

subcribed...

This looks like it has great potential

-J

Bug Eyes 4ev4R
natoli4 04-01-2006 10:05 PM

let's see some updates!!!!
99subi 04-01-2006 10:15 PM

yea some updates, i really want to see how they come out

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