Exposed Headlight housing + Off-road LED’s.

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802SHO

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I got totally inspired by this Drift car that’s got no headlight cover lenses and uses off-road lights for headlights. IMG 9943

The first time I had my headlight covers removed I paid a local guy to do it. Always had the itch to try removing it myself. After several YT videos I found one channel that has great success baking just about every headlight he’s ever modified at 240 for 20 min. It doesn’t create any fumes, it doesn’t melt the headlight plastic that’s sitting directly on the metal shelf. It just gets it nice a pliable. You just need to preheat the oven first and do the full 20 min.

You can leave the headlight wires and everything inside, there’s a small bolt in the upper corner by the fender that needs to be removed before you pull them apart, otherwise just take out the headlight bulb. Work in a corner and remove that bolt, and start gently prying, making sure to clear each tab and it comes apart pretty easy.

I decided on a pair of VisionX 15 degree 3.7” Amber Halo DRL lights. IMG 0056
They will be plenty bright I am getting 2 pairs to use 2 pods per headlight. The Amber DRL can also be a turn signal and when you turn them on they are white LED not Amber. I think the Amber looks like dragon eyes, here is what they look like lit up IMG 0055
Since they are waterproof having no cover doesn’t matter. Under the headlight the cover filled in a large gap of space so I went out and bought 5052 3/16 aluminum sheet metal and made some bottom block off plates. Then came up with a eyebrow too. IMG 0069IMG 0070IMG 0075IMG 0071IMG 0073IMG 0076

I went from cardboard to aluminum and I’ll just rivet them to the headlight housing. I’m at the point now where I can clean them up, touch up the lines and edges and paint them. The off-road lights should be here early next week so I hope to get this done by then. Can’t wait to see how it looks. The bumper slides right on, got some more trimming to do with the chassis splitter and then I’ll wrap it, but it’s good enough to stand on now with no exposed rods here on out. IMG 0081IMG 0080IMG 0082IMG 0084
 

kryptto

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You always have a way to impress me more with something yet to come. Artist. Funny thing my driver side headlight let's water in somehow, and I haven't tried to hunt it down, cause I am waiting for the GH IC, when I take it all apart. Love the inspiration.
 

Ta2dResqr

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I think it looks awesome and is very innovative but, I have to ask, with all of the aero work you have already done, why make such a drag area that doesn't provide a performance bonus? Seems like using the clear lens as an aero shield would still give the same appearance.
 

802SHO

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I think it looks awesome and is very innovative but, I have to ask, with all of the aero work you have already done, why make such a drag area that doesn't provide a performance bonus? Seems like using the clear lens as an aero shield would still give the same appearance.
Good question. I’m going to cut a small area out near the corner of the fender so air can escape in the fender out of the fender vent. Unfortunately with the lower grille and fog light areas removed I’m not able to take full advantage of a chassis splitter. At least the chassis one will be more functional than the last cosmetic one.

I’m passed the point no return with the lenses. All the clips are cut off now. If I’m to redo this I’ll need to buy another set.
 

kryptto

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Good question. I’m going to cut a small area out near the corner of the fender so air can escape in the fender out of the fender vent. Unfortunately with the lower grille and fog light areas removed I’m not able to take full advantage of a chassis splitter. At least the chassis one will be more functional than the last cosmetic one.

I’m passed the point no return with the lenses. All the clips are cut off now. If I’m to redo this I’ll need to buy another set.
Wreckeless disregard for aerodynamics I vote for!
 

802SHO

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Made progress today. I didn’t make the eyebrows for the headlights to serve any real purpose other than for looks, but today they came in perfect for mounting the pods. I ran out to Fastenal to buy some beveled washers. The headlight housing is angled so the beveled washers allowed me to keep the lights level. IMG 0104IMG 0109IMG 0107IMG 0105

Now to power them up real quick to finally see what I’ve been visualizing come to life! IMG 0112
Now this is menacing! Just what I wanted! I love the amber halo it looks so mean IMG 0111
I’ll have to do a nice circuit panel and get the halo’s on their own switch. If I had them on parking lights I’d have my taillights on too and I don’t want that. I found that these lights have a dimmer I can add, they’re pre-wired for dimmer I just need to buy the kit, then I can dim the lights up to 50% so I’m not too bright for night driving. I don’t need to see 900’ down the road at night lol! And when the lights are on they’re just white LED, which I think is awesome. Amber for Halo’s and white when on, perfect. IMG 0113

I can fit a 3rd Pod I’m pretty sure but I wasn’t planning on it. I think I’m just going to cut a vent in the rest of the housing and attach the same grille mesh scrap I have leftover from my grille. But I’d have to cut a hole anyway to add a 3rd light so if I change my mind I can remove the mesh and add another one down the road. Now I need to vinyl wrap some stuff, paint some stuff and finish these up. The hard part is done!
 

802SHO

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Last minute decided to see if I could reuse some of the inner layer headlight shell to cover up the sides. Came out pretty good, it looks cleaner. I need some 1” rivets and it should be pretty secure. I used the inner parking light bulb to do an M10 rivnut, so behind the painted black reflector it’s bolted to the housing. IMG 0119IMG 0123IMG 0120IMG 0121
 

kryptto

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@802SHO I have a leaking driver side headlight, can you come fix it up? Make things easy, bring yours and swap them out, mine are tinted. Call it a fair swap.
 

Joshw0000

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Even though we all know how quick the SHO is, very few look fast sitting still. This is not one of them. Great job.

How do the turn signals look?

Sent from my Pixel 7 Pro using Tapatalk
 

802SHO

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@802SHO I have a leaking driver side headlight, can you come fix it up? Make things easy, bring yours and swap them out, mine are tinted. Call it a fair swap.
At least your tint hides the condensation buildup
Even though we all know how quick the SHO is, very few look fast sitting still. This is not one of them. Great job.

How do the turn signals look?

Sent from my Pixel 7 Pro using Tapatalk
I’ll wire the halo to the blinker.
 

kryptto

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@802SHO you know I was asking myself this question, and haven't read every post in this thread, you planning that car to be a road ready car? Is that a stupid question or track car only?
 

802SHO

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Just about done with these headlight housings. I wrapped the aluminum in the same CF vinyl as my chassis splitter. IMG 0186
3 rivets holding the top behind the molding edge, 4 rivets holding the bottom. I even wrapped the beveled washers the best I could IMG 0187
This is what the M10 rivnut looks like inside the inner lense. May need to add some adhesive to that small crack so it doesn’t grow over time. Kind of expected that fastening a metal rivnut to hard plastic. IMG 0188IMG 0189
Then in the corner I tried to sneak in this little bolt to not be too noticeable. IMG 0190
I’d say about 90% done, the secondary lense in the corner needs to be touched up a little more but overall this is how this unorthodox project came out IMG 0192IMG 0193IMG 0194IMG 0195
 

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