Round two - FULL set of headlights from scratch

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Round two - FULL set of headlights from scratch

October 14, 2007, 11:19:42 PM

since I still have a second pair of Acura TL projectors sitting around, I figure its time to start trying to make a complete new headlight assembly. I don't think I can vacuum form a 1-piece headlight lens so its going to have to be headlight/inner as one light and the corner lamp as a second piece. As we all should know, there is a header panel mounting bar in between the inner markers and headlights so nothing can go there. Other than that, I'm open to ANY suggestions/photoshops you guys may have.

I was thinking of sticking TSX projectors in there for low beams and a seperate projector for highs (or just halogen highs) as they would make custom INTERNAL aiming mechanisms much easier with the 3" height (compared to the Acura TL's 4.6" of mounting height). Anyways, here are the closest two seperate projectors would be able to exist in the front of our cars - photoshop:

Shrouds would be either flat black or vacuum chromed. The shape around the projectors would be far less pr0nounced. Of course, my plans still call for clear corner lights so not sure where to go there either. Marker/signal lights such as here: http://home.comcast.net/~seekproj/DSC_1172.jpg could fit in well.

Round two - FULL set of headlights from scratch

Reply #1 – October 14, 2007, 11:26:41 PM

Wow, I see you're a few steps ahead of me. I was thinking of adapting the newer 2000-ish Impala light assemblies with some custom fender tpuppies and grille shell fitting via sheetmetal repro.

I like it.

Round two - FULL set of headlights from scratch

Reply #2 – October 14, 2007, 11:38:16 PM

Something like this would work well but we have MUCH more width in the front than most newer cars. There just isn't anything reasonable to fill in the inner marker spot with:

Round two - FULL set of headlights from scratch

Reply #3 – October 15, 2007, 12:06:37 AM

My other thought is taking the projectors inward from the TSX and hardwiring LED's into the middle markers to get past the header panel's mounting obstruction. It'd give me one of the best low beam projectors in terms of output and width, plus halogen high beams that don't care as much to be flicked on/off repeatedly (flash to pass, hookup to alarm, etc - ballasts don't like that kind of thing).

Of course, I could steal much of its housing in terms of protecting the projectors from weather and aiming capabilities. There may not be nearly enough mounting depth for this though, as the inner parts sit in quite a bit.

Round two - FULL set of headlights from scratch

Reply #4 – October 15, 2007, 12:12:05 AM

Well, either way would be really interesting.

I'm kinda thinking the TSX's would look better IMO, just because of the halogen lights don't look so ?weird? compared to the projectors.

I REALLY want to see this work in progress, and the final results!!!!

Round two - FULL set of headlights from scratch

Reply #5 – October 15, 2007, 12:30:21 AM

They can be done, but of course I'd have to use/chop off the reflector from another set of lights so that they may be mounted forward more so I may aim it straight. Using the TSX's reflector would likely render the amber light unusable since it attaches to the reflector near its peak/front. We're then back to having a gaping hole in between the projector and reflector unless something else can be mocked up in between (not easy as all the factory lights have perfectly smooth curves or very straight lines).

The current setup is here: http://home.comcast.net/~seekproj/HID4.jpg
Its much more silver in person and looks better with the other lights off. I'll see if I have a picture. Either way, its the best I could do without merging front lights together.

Round two - FULL set of headlights from scratch

Reply #6 – October 15, 2007, 12:37:15 AM

My only shot with them off it seems is at the track

Round two - FULL set of headlights from scratch

Reply #7 – October 15, 2007, 12:44:04 AM

Quote from: Seek;182556

Something like this would work well but we have MUCH more width in the front than most newer cars. There just isn't anything reasonable to fill in the inner marker spot with:

Those are SICK!!! A TC header panel modified to fit those would jut be HOT!!! What are they from?

PS - Hi myself and Layla in the pic! :hick:

Round two - FULL set of headlights from scratch

Reply #8 – October 15, 2007, 01:07:11 AM

Early 90's Lexus ES300. Older halogen projectors but a nice headlight design. It IS possible to do a similar design without chopping the car apart if you didn't mind the sharper corner. It would have to be split at the orange reflector though as it just isn't feasible without a lot of time/$$$ to make a lens that wraps completely around the front lights AND the rear of the corner lamp...it'd require a more special vacuum forming setup to suck from the middle of the chamber instead of from the bottom. No help from gravity at all then.

Round two - FULL set of headlights from scratch

Reply #9 – October 15, 2007, 01:14:00 AM

Early 90's ES300. Older halogen projectors. It IS possible to do a similar design without chopping the car apart if you didn't mind the sharper corner. It would have to be split at the orange reflector though as it just isn't feasible without a lot of time/$$$ to make a lens that wraps completely around the front lights AND the rear of the corner lamp...it'd require a more special vacuum forming setup to suck from the middle of the chamber instead of from the bottom. No help from gravity at all then.

Round two - FULL set of headlights from scratch

Reply #10 – October 15, 2007, 06:49:25 AM

I just wish the aftermarket made a nice one piece light assembly for our Birds like they do for the Mustangs (Fox bodies).There's are pretty cheap also.I wonder if the projector beam Stang lights could be grafted into our cars,meaning,take the projector beam Stang lights,cut the bucket assembly (or most of it),and graft it into our bucket assembly and add clear light covers?

Round two - FULL set of headlights from scratch

Reply #11 – October 15, 2007, 09:53:31 AM

Except they make the Mustang ones in batches of 10,000. We would be hard pressed to sell 100.

Round two - FULL set of headlights from scratch

Reply #12 – October 15, 2007, 04:43:10 PM

You do have a point there,Mike.

Round two - FULL set of headlights from scratch

Reply #13 – October 15, 2007, 10:00:54 PM

I'm surprised no one has any input. People love body kits and spoilers but don't want to mess with a DECENT set of headlights. Even new with 14.6v at the bulb the output wasn't all that great (hotspots) on the stock lights. The fogs helped somewhat with lighting everything up with glare but still lit up horribly against any non 9004-bulb vehicles (with exception of vans with two hotspots going down the road...in this case it was always nice to get back behind the bird's wheel).

With HID projectors its like highbeam output x2 all the time, nor does it care about 12v or 14v for output. Just a nice healthy 6,000 lumens right there on the road where you want it. Go with Philips' 50w bulbs in an overdriven 70w ballast (I think they've all been modified at this point - bosch, hella, matsushiznita, etc) and you have an illegal 12,000 lumens around 4500-5000 kelvin (35w bulbs ran at 70w will push the color into the 5000-6000 range).

Plus, you can glisten going down the road if you wish (mine are aimed a little down right now...doesn't flicker at the mirror level on other cars). Of course, it all comes at a price of up to $1000. Going cheap with FX35 projectors ($60), pair of used OEM ballasts and bulbs ($120), a clear lens ($50-100), and a little creativity can get a bi-xenon setup finished for $300.

Its too bad I can't keep the stock headlight appearance (they're not too bad looking when clean) AND have good illumination. I've always been function over form though so safety > looks.

Round two - FULL set of headlights from scratch

Reply #14 – October 15, 2007, 11:07:59 PM

I'm liking your first photoshop up there. I actually drew a pic like that about 10 years ago, fantasizing (I was thinking more along the lines of 2nd gen Integra lights when I drew it though).

As for what to do about corners, how about something like what I'm doing (pics below)? I used white resin (resin not shown in "off" pic) and painted the reflectors white because my car is white. You could use your choice of colours for the LED's of course - I used amber for PARK and white for TURN. I think they'd look badass in black on a black car...