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  #61  
Old 08-14-2010, 12:52 AM
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Re: Design my NEW headlights!

I agree, I want full coverage so nothing from the projector will leak out. Also, I simply do not like the look of a shroud stuffed into the stock reflector. It looks okay, but at the same time it almost appears like its not done. This way I will be able to do a nice custom enclosure...hopefully!
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  #62  
Old 08-14-2010, 01:38 AM
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Re: Design my NEW headlights!

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Originally Posted by kerndone View Post
I agree, I want full coverage so nothing from the projector will leak out. Also, I simply do not like the look of a shroud stuffed into the stock reflector. It looks okay, but at the same time it almost appears like its not done. This way I will be able to do a nice custom enclosure...hopefully!
I hear ya, I plan on "trying" to make a fiberglass base and seeing how well I can fit/paint it, form there Ill compare to the shrouds only look possibly? Im thinking some sort of base will be in order being as I may ditch the reflectors. Thats my main dillema now, to remove reflectors and mod accordingly or ditch them all together? hmmmmm decisions, decisions - btw posted in your thread
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  #63  
Old 09-07-2010, 09:17 PM
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Re: Design my NEW headlights!

Hey guys, I know its been awhile. Was on vacation and busy moving to a new apartment. This is my first and last week home with not much to do so Im trying to get these done.

As of now: I have everything disassembled and the reflectors separated from the housing with some force. One housing cracked and an adjuster broke, but I epoxied it back together so it should be fine fingers x'ed!.

I currently have a cardboard cutout mount drawn/mached up and having a custom 10 guage aluminum piece cut to fit tomorrow hopefully. Using that, I am going to toss the reflectors as they make for a horrible mounting surface beign as its concave, so Id rather go flat and custom cut/drill a piece out . . . so I am lol.

From there, I plan on using the parts that came on the reflector that are used for the tilt adjustment. I am going to use those pieces and attach them to the the metal frame which the actual projectors will be flush mounted to. This way I can retain the factory tilt movement and keep the projectors adjustable up and down ways. They will obviously be straight being as its a flat surface to a flat surface so they should be aimed perfectly minus the up/down part

Then I plan on covering the metal base (if you will) in some nice 3m dinoc stuff possibly, unless anyone thinks the heat will get to it? But I know its rated for pretty good temps outdoor and I dont know how hot it gets inside the housings, anyone have an accurate idea? If not I plan on painting it all a satin black (similar to Robs) with some high temp clear over so that should last ok if the CF doesn't pan out.

The way it will work/look is that the projector units will come through the back of the custom mounts I'm having made and sit right flush with the pre-existing hole in the black plastic exterior frame, like it normally should. The trick will be in mounting the projector down to the custom frame without having all the projector showing. The GTI shrouds I got are a little tiny and don't cover it completely so I may need to find alternative shrouds or figure out a way to have the projector lens and the frame showing and not the screw holes where it mounts. Suggestions welcome

Thats it for now, pics to come later when I take them, sorry no camera right now Keep ya posted guys.
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  #64  
Old 09-07-2010, 09:23 PM
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Re: Design my NEW headlights!

good luck!!
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  #65  
Old 09-08-2010, 11:47 AM
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Re: Design my NEW headlights!

I like your plan. It sounds great and I hope it works out. I have been too busy to get anything done, but I did acquire some materials to coincidentally do something similar to what you mentioned. I, however, simply bought some flat stock that I am going to use to make brackets and mount the projector directly to the housing. I have a spare broken housing, so I thought I might as well see how that way turns out too! I'm really curious to see how your mount turn out. My issue is figuring out how to cut the reflector so I can still retain the high beam side, yet make sure its hidden on the low beam side. I'm thinking a fiberglass shroud is what will be needed. I will try to mock up that side this weekend just to see how it might work out. Keep us posted on your progress.
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  #66  
Old 02-17-2011, 08:03 PM
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Re: Design my NEW headlights!

bump, project is back underway! Sorry for delay, school and work at same time consumed me so Im lucky I could do anything. Starting to slow down now and get closer to graduation so I have some time for mods now, so yeah, I know its been like 6 months but hey thats how I mod, 6 months at a time lol.

Kerdone curious to see where/how you made out with yours? Lots of guys have been doing this since September lol so Im ancy to get it going and done! Weathers warming back up here in the tri-state. 70 tomorrow so hopefully I can make some progress! Keep whoever cares posted!
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  #67  
Old 02-18-2011, 03:28 PM
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Re: Design my NEW headlights!

I am with you, life has been going pretty quickly lately so this got put on the back burner. I had both of my projectors mounted in the stock reflectors and ready to go, but I was not comfortable with the proximity to the front lens of the housing. I scratched that idea and I am going to retain the high beam reflector, mount a bracket that attaches the projector to it and then I will have one additional mount on the housing itself. I have already begun my shrouds, I will take some pics after work and show you how its going. The mounts are still being "fabbed," but I should have a mocked up version soon.

Good luck with yours!
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  #68  
Old 02-21-2011, 07:37 PM
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Re: Design my NEW headlights!

Quote:
Originally Posted by kerndone View Post
I am with you, life has been going pretty quickly lately so this got put on the back burner. I had both of my projectors mounted in the stock reflectors and ready to go, but I was not comfortable with the proximity to the front lens of the housing. I scratched that idea and I am going to retain the high beam reflector, mount a bracket that attaches the projector to it and then I will have one additional mount on the housing itself. I have already begun my shrouds, I will take some pics after work and show you how its going. The mounts are still being "fabbed," but I should have a mocked up version soon.

Good luck with yours!

Awesome, cant wait to see. I really need to plan this one out, I just looked at all the crap I had stashed away and after looking at it and being broke a the moment Im like damn, I have like $600 worth of crap in here and I certainly cant afford to mess anything up and reorder parts haha. Really want to get this one done properly and the first time at that haha!
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  #69  
Old 02-22-2011, 05:17 PM
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Re: Design my NEW headlights!

maybe try the newer minimotos like I got in my current dual projector project??



Im currently painting halo rings/soldering them before I do further test fitting/beam aiming
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  #70  
Old 02-22-2011, 05:18 PM
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Re: Design my NEW headlights!

I also used the e46 EXTENDED shrouds

as you can see, they fill the projector circles up AND have an edge line that matches the factory edge line in each projector too!!
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  #71  
Old 02-24-2011, 06:50 PM
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Re: Design my NEW headlights!

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Originally Posted by pmpn8ez View Post
I also used the e46 EXTENDED shrouds

as you can see, they fill the projector circles up AND have an edge line that matches the factory edge line in each projector too!!
Yeah? How do you like those e46 shrouds overall? Definitely like to hear some more info on how you did this if you did do it? Im still on the planning and cutting phase haha. Trying to fab these up in a way that I still have full adjustability so we'll see.

I got the FX-R projectors jsut due to the ratings and great reviews Ive heard on the sharp cutoff and overall projector quality, and price haha. You like the minis so far, ever fired them up? Def would like to hear/see more before I really commit to something. I can definitely still swap projectors and shrouds but Ive test fit what I have so Im going to need to decide very soon haha. Want my lights done for Spring hopefully! Finger x'ed
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