After market headlights, final fitting to occur when the car gets painted Options

[Mike Bellis]

I am doing another set too. TurboWalt has commisioned my services to build him a set. We should start a new combined thread specifically on this conversion. Oh wait, this is the thread. Just make sure your car is ready for the Dog Days Drive!

You want to make me a set too? Pm me with price and how they will fit...I like this idea a lot!

You are looking at about $300 in materials including HID lamp kit and fiberglass + misc. If you want parabolic lenses, add more $. Labor is undetermined. I have at least 16 hours into mine but I'm hoping to cut the time down with the next set. TurboWalt is in Iraq right now and not hounding me to be done. I should have his set done in about a month, since I still have a day job and kids.

[Ferg]

I want to see somebody integrate these into a 914 hood

http://www.youtube.com/watch?v=6oVFRe2kkXE

(IMG:style_emoticons/default/shades.gif)

[Mike Bellis]

I want to see somebody integrate these into a 914 hood

http://www.youtube.com/watch?v=6oVFRe2kkXE

(IMG:style_emoticons/default/shades.gif)

If they wern't so ugly... (IMG:style_emoticons/default/barf.gif)

[matthepcat]

I am doing another set too. TurboWalt has commisioned my services to build him a set. We should start a new combined thread specifically on this conversion. Oh wait, this is the thread. Just make sure your car is ready for the Dog Days Drive!

I know! I want to go on that drive. It's quite far though, and I am not that confident in my car yet.

Just doing my first tape off of the housing....measure...double measure....second guess...remeasure. Eventually I have to cut (IMG:style_emoticons/default/wacko.gif)

[Cap'n Krusty]

Pretty cool and unique! I would put them on my car in a heartbeat! They would look awesome as a pop-up or a roller light ala Corvette.

It would be easy to recess these under plexyglass with a custom bucket. Smoked plexy so you don't see anything. You could simply cut 2 holes in the rear of the bucket and 4 small holes for the adjustment studs.

Flip over would take much more fab time.

You could change the geometry of the pivot to open less, and have these pop up under factory lids. Custom trim around so it looks factory

Smoked plexi, or ANY plexy, covering the lights is also illegal in CA. (Just like plexi over your license plates.) The new cars with plexi light housings are designed that way, and carry DOT approval as such. Yours won't have that approval, and the wrong cop could make your day miserable.

The Cap'n

[Mike Bellis]

I am doing another set too. TurboWalt has commisioned my services to build him a set. We should start a new combined thread specifically on this conversion. Oh wait, this is the thread. Just make sure your car is ready for the Dog Days Drive!

I know! I want to go on that drive. It's quite far though, and I am not that confident in my car yet.

Just doing my first tape off of the housing....measure...double measure....second guess...remeasure. Eventually I have to cut (IMG:style_emoticons/default/wacko.gif)

Cut them 1/4 inch bigger on the sides and back. Cut 1/2 inch bigger in the front. Once you have the rough cut, slowly cut to size. Cut the front to size after the other 3 are done.

[rickthejetman]

what h7/halo kit did you use? i dont seam to be able to find any meant for headlights only fog lights. i really like what you did but i think im going to go with the stock lids and change the pop up geometry so they only come up enough to reveal the projector.

[Mike Bellis]

what h7/halo kit did you use? i dont seam to be able to find any meant for headlights only fog lights. i really like what you did but i think im going to go with the stock lids and change the pop up geometry so they only come up enough to reveal the projector.

Search ebay for Nissan 240sx halo and you will find them. They mount to the housing with 3-4 studs and could be used in a custom bracket for your project.

[rickthejetman]

what h7/halo kit did you use? i dont seam to be able to find any meant for headlights only fog lights. i really like what you did but i think im going to go with the stock lids and change the pop up geometry so they only come up enough to reveal the projector.

Search ebay for Nissan 240sx halo and you will find them. They mount to the housing with 3-4 studs and could be used in a custom bracket for your project.

thank you very much for the info i didnt even think to look an evilbay.

[matthepcat]

Ok....so this job is not easy. Took about 4 hours to tape off and cut last night.
Here are some photos of the process:


Carboard cut-out
(IMG:http://www.914world.com/bbs2/uploads_offsite/img844.imageshack.us-11125-1280430059.1.jpg)

Use to mark cut location.
(IMG:http://www.914world.com/bbs2/uploads_offsite/img339.imageshack.us-11125-1280430059.2.jpg)

Tape it out
(IMG:http://www.914world.com/bbs2/uploads_offsite/img835.imageshack.us-11125-1280430059.3.jpg)

Measure
(IMG:http://www.914world.com/bbs2/uploads_offsite/img94.imageshack.us-11125-1280430059.4.jpg)

The hard part.....cutting.
(IMG:http://www.914world.com/bbs2/uploads_offsite/img194.imageshack.us-11125-1280430059.5.jpg)

Cut off nissan mounting plastic
(IMG:http://www.914world.com/bbs2/uploads_offsite/img838.imageshack.us-11125-1280430060.6.jpg)

Lots of trimming and marking and sanding and trimming (time consuming)

(IMG:http://www.914world.com/bbs2/uploads_offsite/img819.imageshack.us-11125-1280430060.7.jpg)

Not bad for a first cut & fit
(IMG:http://www.914world.com/bbs2/uploads_offsite/img210.imageshack.us-11125-1280430060.8.jpg)

Old headlight vs new
(IMG:http://www.914world.com/bbs2/uploads_offsite/img217.imageshack.us-11125-1280430061.9.jpg)

Now it's time to go to bed, perfecting fit & painting & retrofit HID projector after sleep:
(IMG:http://www.914world.com/bbs2/uploads_offsite/img375.imageshack.us-11125-1280430061.10.jpg)

[Mike Bellis]

Very nice. The only thing I did different is the template. Mine was larger and sliped over the new light. I used 4 pieces of cardboard to make the outside template.

[matthepcat]

Yea that would have been a better method. I mostly depended on measurements off the template and used a strait edge.

Your are correct that there are NO perfect angles on this car, especially taking into account any bodywork in the headlight area & how the hood is mounted.

If your hood is very slightly mounted off center, one headlight area will be modified much differently from the other side.

Mike,

Did you glue the housing to the L-brackets?

Matt

Very nice. The only thing I did different is the template. Mine was larger and sliped over the new light. I used 4 pieces of cardboard to make the outside template.

[Mike Bellis]

Yea that would have been a better method. I mostly depended on measurements off the template and used a strait edge.

Your are correct that there are NO perfect angles on this car, especially taking into account any bodywork in the headlight area & how the hood is mounted.

If your hood is very slightly mounted off center, one headlight area will be modified much differently from the other side.

Mike,

Did you glue the housing to the L-brackets?

Matt

Very nice. The only thing I did different is the template. Mine was larger and sliped over the new light. I used 4 pieces of cardboard to make the outside template.

I build up the bottom surface with "Kitty Hair" Fiberglass. about 0.5-.75 inch. Bolt the L brackets to the car first. You should be able to set the lights loose on to the brackets. If everything lines up good, place some wet kitty hair on the top of the brackets. lower the light on to them. Wait until it dries and un bolt the L brakets. Remove the lights with attached L brackets and re-enforce the bottom area with more kitty hair. I also add 10-25% gel in my kitty hair to make it flow better. Rough up the bottom ABS before attaching kitty hair. this will help it adhere. Then sand and fill, sand and fill. when you get close to perfect, spot putty will be your friend. You may find the need to slightly twist the fixture to get it in and out wth the brackets installed. I used Rivet nuts on the L brackets and bolts in the factory pivot holes. Only 1 bolt inside the fender and 2 under the hood holds it perfect.

[matthepcat]

Here is a little update.


Currently I have the HID projectors into the housings. They barely fit!

Originally I cut open the stock housing to make both lights look the same, but found there was not enough room for them to look right.

I am currently in the process of making shrouds for the projectors, finding the easiest mounting solution( I am using a ghetto zip-tie method), painting and finally aiming.


Here is what they look like now:

(IMG:http://www.914world.com/bbs2/uploads_offsite/img836.imageshack.us-11125-1282353225.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/img708.imageshack.us-11125-1282353225.2.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/img691.imageshack.us-11125-1282353225.3.jpg)

[TurboWalt]

I pulled the trigger and am becoming a copy cat.

Accept I am going to try to retrofit a Bi-Xenon projector into one of the halogen housings. That part may be tough (IMG:style_emoticons/default/rolleyes.gif)

(IMG:http://www.914world.com/bbs2/uploads_offsite/img693.imageshack.us-11125-1280352749.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/img525.imageshack.us-11125-1280352749.2.jpg)

Wish me luck.

Matt,

Any luck with fitting the Bi-Xenon's?

Walt

[matthepcat]

Hey Walt,

Yea I got them in there as in the photos above. I had to make some custom adjustment screws.
Once I get the shroud fabricated it will look nice.

The lights are wired up and functional. (high & low beam bi-xenon)

I am using one of the smallest bi-xenon projectors called : Morimoto Mini

The best place to get them is www.theretrofitsource.com

(IMG:style_emoticons/default/smile.gif)

I pulled the trigger and am becoming a copy cat.

Accept I am going to try to retrofit a Bi-Xenon projector into one of the halogen housings. That part may be tough (IMG:style_emoticons/default/rolleyes.gif)

(IMG:http://www.914world.com/bbs2/uploads_offsite/img693.imageshack.us-11125-1280352749.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/img525.imageshack.us-11125-1280352749.2.jpg)

Wish me luck.

Matt,

Any luck with fitting the Bi-Xenon's?

Walt

[charliew]

Is this kit the one you guys started with? It comes with a hid upgrade I think and think it says it's only hid in low beam so only two lights in low beam and two in high beam? I'm not up to speed on the new lights very well. I was understanding the lights you are using were all four on high and low beam and that should be brighter it seems especially if one were to fail.

http://cgi.ebay.com/ebaymotors/89-94-NISSA...rts_Accessories

[Mike Bellis]

Is this kit the one you guys started with? It comes with a hid upgrade I think and think it says it's only hid in low beam so only two lights in low beam and two in high beam? I'm not up to speed on the new lights very well. I was understanding the lights you are using were all four on high and low beam and that should be brighter it seems especially if one were to fail.

http://cgi.ebay.com/ebaymotors/89-94-NISSA...rts_Accessories

Basically yes. I buy the HID kits separate from the lamp housing. That is a good price if it includes 4 bulbs and balasts too. I prefer the 4300K (Kelvin) lamps. It it the brightest in Lumens and is yellow/white in color.

[charliew]

I get the jist of it to be two extra hid bulbs and ballasts with the regular four halogens and instructions on changing two halogens out with the two hid's, with a choice of four different colors, 6000,8000,10,000 and 12,000.

[Mike Bellis]

I get the jist of it to be two extra hid bulbs and ballasts with the regular four halogens and instructions on changing two halogens out with the two hid's, with a choice of four different colors, 6000,8000,10,000 and 12,000.

With a 6000 and higher color you will get about the same Lumens as the Halogens. 6000K is actually blue not white. 5000K is the highest you should go. There is a guy on Ebay in San Jose that sells HID kits for $40 per pair. I use him often. He has 4300K and 5000K in stock.

Ricer guys like the looks of blue/purple lights but they do not reflect well. The night vision will be worse than you have with stock sealed beam lamps at 12000K. All the reflected light will be dark purple.