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  #49  
Old 08-12-2010, 06:30 PM
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Re: Design my NEW headlights!

Bump - heres all the stuff guys:



Two (2) NEW 2005-2007 Jeep GC Headlamps
Four (4) FX-R Projectors w/ bi-xenon actuator plugs
Two (2) Morimoto Ballasts
Four (4) Morimoto 5k HID Bulbs
One (1) 9006 relay harness
Four (4) Apollo Projector Shrouds
Four (4) DS2 HID Adapters

I already have an HID kit w/ a relay setup and 2 ballasts so thats why I got one morimoto his setup w/ relays and 4 adapaters Get ready to see some sick headlights when its all said and done. Ill keep you all posted through this thread
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  #50  
Old 08-12-2010, 07:51 PM
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Re: Design my NEW headlights!

gonna look nice... def make us a HOW TO on this.
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  #51  
Old 08-12-2010, 08:27 PM
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Re: Design my NEW headlights!

Can't wait to see it to the end
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  #52  
Old 08-12-2010, 09:25 PM
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Re: Design my NEW headlights!

Looks like my room...minus two projectors. I'm a bit jealous actually.
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  #53  
Old 08-12-2010, 09:47 PM
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Re: Design my NEW headlights!

thanks guys! heres a little sneak pic I guess you could call it haha. Started in on some disassembly tonight after dinner, think Im gonna call it a night ad get out in the shop tomorrow morning. Keep you guys posted, probably do a DIY thread



NOT SURE how I am gonna separate the reflectors. Kerdone, I saw how you said you did it, just not sure I want to attempt that. May not separate at all. Thinking I can dremel or hole saw right through to make the appropriate size hole. Then Im going to sit down and draw up the mounting setup, that'll be majority of my work Id say. For all who are wondering, the aftermarket OEM headlights are nice, but certainly cheaper than OEM and quality shows.

FTR, theretrofitsource is great, good stuff over there!
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  #54  
Old 08-12-2010, 10:22 PM
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Re: Design my NEW headlights!

edit: looks like the Apollo shrouds are a little large for my liking and fitment isn't quite there on the FX-R's, I'm going to have Matt swap them out for 4 new GTI shrouds tomorrow. Also forgot to mention I'm going down the shore for a few weeks for my ONLY vacation all year haha so this project will be put on a little hold. No big deal though, early September Ill have those badboys up and running. Ill still be active on here too, so no worries

Also to note, rather than remove the reflectors w/ the idea of putting them back in, I think I may ditch them 100% and simply have the projectors ad shrouds as well as the painted main unit bezel thats in the pics above. I figure I don't need the reflectors for functionality, and looks wise they're nothing much, so its probable I'm gonna bust them out of there carefully haha. keep you posted w/e I do. All in time, all in time.
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  #55  
Old 08-12-2010, 10:31 PM
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Re: Design my NEW headlights!

Quote:
Originally Posted by kerndone View Post
Just ordered all of my materials to do a full fiberglass shroud/base underneath my E46-R shroud. My plan is to completely cover the reflector on the low beam side. I can't wait to get this thing mounted up to determine how the rest of the light is going to come together.
Good call. That's what I did on my DubJ retrofit and it worked out great. Fiberglassing ensures a perfect fit and performance. Have you decided how you plan to shape them?
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  #56  
Old 08-12-2010, 10:34 PM
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Re: Design my NEW headlights!

Quote:
Originally Posted by JDubya View Post
Good call. That's what I did on my DubJ retrofit and it worked out great. Fiberglassing ensures a perfect fit and performance. Have you decided how you plan to shape them?
hmmmm Fiberglass, I'm game to try that, how would one go about making a base, just laying it inside the shroud and let it harden and then cut out the hole and you put the projector inside that? Rough idea but you know what I mean lol
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  #57  
Old 08-12-2010, 11:16 PM
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Re: Design my NEW headlights!

Quote:
Originally Posted by soontobesrt View Post
hmmmm Fiberglass, I'm game to try that, how would one go about making a base, just laying it inside the shroud and let it harden and then cut out the hole and you put the projector inside that? Rough idea but you know what I mean lol
I'll try to explain how I did it. Once the projectors were aimed properly and permanently mounted, I covered everything in painters tape. Then I draped a piece of fleece (that has some stretch) over the reflector and projector and secured it to the projector lens holder with a hose clamp. Doing this will keep the fiberglass shroud offset from the lens a little so that you can still use a decorative bezel of some sort. After that I wrapped the fabric around to the back of the reflector and attached it with spray adhesive. Now mix up some fiberglass resin and paint it onto the fleece. For the edge/back, only apply resin around the very edge to give it a "lip" (the resin will release the spray adhesive so make sure you use the adhesive on more than just the edge). When it's completed, this lip will allow the shroud to sort of snap into place. It'll also give you an easy way to adhere it using RTV silicone (or whatever you prefer). Don't put any resin on the hose clamp, stop just before you get to it.

If you want an ultra-smooth finish, you can apply a second (or more) coat of just resin. Mix it up and just pour it on, let it drip off. Once you're happy with the finish and it's dry, you can pop it off and trim it. If you think it's too flimsy or fragile, add some cloth/resin to the underside.

I hope that made sense... does it?
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  #58  
Old 08-13-2010, 02:08 AM
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Re: Design my NEW headlights!

Jdubya hit it pretty much on the head. I think it makes perfect sense, although I have been doing a decent amount of research on fiberglassing so I may be biased. I ordered some US Composite B-440 polyester resin for the hardener, some Duraglass for the buildup of certain areas and finally some Rage body filler to smooth everything out. I will source the fiberglass chop mat for strength and the fleece locally. Do a google search for the items I mentioned and you should get a good idea of what you need to buy. Also search for a how-to on fiberglassing; it should yield some sufficient results. Most how-tos will involve sub enclosures...great info on those projects.
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  #59  
Old 08-13-2010, 11:37 PM
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Re: Design my NEW headlights!

Quote:
Originally Posted by kerndone View Post
Jdubya hit it pretty much on the head. I think it makes perfect sense, although I have been doing a decent amount of research on fiberglassing so I may be biased. I ordered some US Composite B-440 polyester resin for the hardener, some Duraglass for the buildup of certain areas and finally some Rage body filler to smooth everything out. I will source the fiberglass chop mat for strength and the fleece locally. Do a google search for the items I mentioned and you should get a good idea of what you need to buy. Also search for a how-to on fiberglassing; it should yield some sufficient results. Most how-tos will involve sub enclosures...great info on those projects.
Im semi familiar with fiber-glassing and have some stuff outside that may work, just not sure why I should do it haha? Are you guys having fitment issues with the shrouds or is this more to fill the gap between the shrouds and the reflector shape so no light gets out? Id say the later but I think I can fit the shrouds perfectly onto the projectors and they should line up nicely in the reflector w/ minor trimming? I may try what you suggested and if its not pleasing just ditch it. Thanks for the write-up though haha.
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  #60  
Old 08-13-2010, 11:53 PM
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Re: Design my NEW headlights!

Quote:
Originally Posted by soontobesrt View Post
Im semi familiar with fiber-glassing and have some stuff outside that may work, just not sure why I should do it haha? Are you guys having fitment issues with the shrouds or is this more to fill the gap between the shrouds and the reflector shape so no light gets out? Id say the later but I think I can fit the shrouds perfectly onto the projectors and they should line up nicely in the reflector w/ minor trimming? I may try what you suggested and if its not pleasing just ditch it. Thanks for the write-up though haha.
Bingo. The only light you see should come through the projector.
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