Headlights Galore! *Projectors inside*

[intimdatr]

Some of you all I'm sure have been following my headlight 'testing' over the past year or so. I finally jumped up to a pair of the big boys. FX-R 3.0s. For those that don't know these are about the best aftermarket for the money projector out there. I'm using the Morimoto XB35 5000k bulbs that are built for 55w ballast and man are they bright. (I'll get some light output pictures this weekend)

Here a few pictures, I apologizes for them being iPhone quality.

Here's the difference in my old projectors and the new ones.

Left is Morimoto Mini H1s. Worked well but i burnt the chrome off the bowls with 55w ballast. Oops. Lol





These are the size of the holes i had to cut, then i ended up cutting out a crap load more plastic to end up getting them to fit. These things are huge. used a 3in hole saw to get these holes






Here you can kinda see how cutting looks, ain't purdy..





What the end product is gonna look like minus the shrouds which i haven't picked out yet. They're going to have to be small to fit in there with the rest of the projector.

 

[EL SHO]

Really impresive work!

Too bad there are not clear headlights for our Gen2 cars. Do you think that the clear covers from SHO Source would last if used as permanet cover?

Patent this design and sell it for good money

 

[intimdatr]

Really impresive work!

Too bad there are not clear headlights for our Gen2 cars. Do you think that the clear covers from SHO Source would last if used as permanet cover?

Patent this design and sell it for good money

Ive been using the SHOsoruce GTS headlight covers for both my 1st gen and 2nd gen setups. They help up pretty well. and kept enough of the water and debris out of the housing. Never had any issues with them.

 

[intimdatr]

More pics here. I'll get some of the light output once i get he radiator and starter back in.

 

[SHOdded]

That's the lighting a SHO deserves!

 

[intimdatr]

That's the lighting a SHO deserves!

Lol wait till tomorrow when i get to move it out of the garage and show off the light output. Its around 2000 lumens vs a stock halogen that's 1000 lumens. Its going to be the bees knees.

 

[intimdatr]

 

[SHOdded]

Great way to blind yourself

 

[sperold]

Thanks for sharing all the great information on projector headlights. I still know nothing about them (like there is a shutter that drops down to give you low beams???), but I do know that all my SHOs have poor headlights, and it takes away from the quality of the experience.
Does that reflective back of the housing do any good with a projector headlight?
My opinion is there is a semi-crazy look to that black dot in the center of the rectangular housing. Can that be improved?
Great project.

 

[intimdatr]

Thanks for sharing all the great information on projector headlights. I still know nothing about them (like there is a shutter that drops down to give you low beams???), but I do know that all my SHOs have poor headlights, and it takes away from the quality of the experience.
Does that reflective back of the housing do any good with a projector headlight?
My opinion is there is a semi-crazy look to that black dot in the center of the rectangular housing. Can that be improved?
Great project.

Yes there is a shutter that is controlled by a magnet that moves a shutter up and down for Hi/lo beam. Pretty cool idea makes for instant transitions between the 2.

The reflective part that that is important to the projector is all contained inside the projector itself. All the chrome inside the headlight housing is just there this point because it looks cool. Lol

My opinion is there is a semi-crazy look to that black dot in the center of the rectangular housing. Can that be improved?

Not quite sure what you mean here?

 

[sperold]

If the original covers (that have a cut diamond patterned surface) were used, how big of a hole would have to be cut in the patterned part (to not affect the projector cone of light coming out). That way you see less of the projector body.

Would a special harness need to be installed?

 

[intimdatr]

It doesn't work at all. I held one up in front one time the light pattern was completely useless.

TO HIDs in general you need a harness that designed for it that has a relay in it to run the HI/LO function. A new harness is always nice too since ours isn't know for being great.

 

[sperold]

I was thinking more like you would cut a hole in the cut diamond surface and put a clear insert in the outer casing. The cone of light from the projector would shine out through the clear section that was added.

 

[intimdatr]

I was thinking more like you would cut a hole in the cut diamond surface and put a clear insert in the outer casing. The cone of light from the projector would shine out through the clear section that was added.

Ahh! The hole would have to be pretty pig. I could look more this weekend about how but the hole would need to be. I have an idea of about 4 inches, if not more. However i think it would look a little funny. Lol

I shall research more when i get home. I made need another set of housing...

 

[sperold]

Great project.

I always wondered why companies improved the rear lights of Gen 2 cars (when there was no issue with the originals); and left the headlights out of the improvement plans(which need improvement).

I looked on the webpage for Morimoto, and got a partial answer. Without knowing what harness to choose, I could not come up with a firm price, but it looks like it might be expensive.

Do you have an idea of costs.... and how would the high/low change occur.
Would it work with the existing multi-function switch on the column?

Again, Great Project.

 

[dohcsable]

I was thinking more like you would cut a hole in the cut diamond surface and put a clear insert in the outer casing. The cone of light from the projector would shine out through the clear section that was added.

Why? Just dismantle the housings, use two to make a plaster mold and then make concrete headlight replica's......then build a jig to put plastic in your oven. Once hot, push the hot plastic down over the concrete replicas. BOOM, clear lenses that after some trimming can be glued to the factory housings.

 

[intimdatr]

Great project.

I always wondered why companies improved the rear lights of Gen 2 cars (when there was no issue with the originals); and left the headlights out of the improvement plans(which need improvement).

I looked on the webpage for Morimoto, and got a partial answer. Without knowing what harness to choose, I could not come up with a firm price, but it looks like it might be expensive.

Do you have an idea of costs.... and how would the high/low change occur.
Would it work with the existing multi-function switch on the column?

Again, Great Project.

You would use a 9007 harnesses brand doesnt make a huge difference but I'm using a DDM tuning harness. Harness arent super cheap but its one of the cheaper parts of the job.

Total cost? its gonna be a lot. To do it yourself is gonna be around 500, easy. If were to make sets to sell its gonna be more.

No messing with the multi function switch, the harnesses join up with the stock harness and and uses relays to do the hi/lo

Why? Just dismantle the housings, use two to make a plaster mold and then make concrete headlight replica's......then build a jig to put plastic in your oven. Once hot, push the hot plastic down over the concrete replicas. BOOM, clear lenses that after some trimming can be glued to the factory housings.

Thats the plan. I have started that for the 2nd gens.I need to do it for the 1st.

 

[intimdatr]

Vacuum forming for the win.

 

[dohcsable]

Vacuum forming for the win.

Thats the other option.....normally more expensive though.

 

[intimdatr]

Thats the other option.....normally more expensive though.

I think its likely the better option. Easier to prevent kinks and bad molds. But i may try the other way soon.. Much cheaper and easier since I wouldnt have to make a positive from the negative.