Forums/Z31P/z31-performance-upgrade-forums cosmetic-interior-exterior/bixenon Projector Retrofit. **kouki retro in progress**
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862sik: (2012-02-10 06:14:01)
I was not pleased at the results aftermarket housings have with HID. Even though there is more light, there isnt that much "usable" light and glare is everywhere. I purchased these projectors from http://www.theretrofitsource.com. They are the Morimoto mini H1. They include a solinoid that will enable high beams, and they are compact.
I also did not like it when others have hids with light all over the place. Hopefully selling a few of these will help those in need.
As you can tell, I will be doing a few of these to sell.
Image of the projector, the shroud I am holding is for another car.
I picked up these Pilot brand sealed beam conversions. They cost a few bucks more than the standard ebay brand. But they have a plastic lens, not cheap glass, so they will last a long time..and not crack.
I put it in the oven for a few minutes to seperate the plastic. 250 degrees for 7 minutes.
Made alignment marks and cut a big hole so the projector can sit back.
Proposed fit with shroud, I may let it float 1/4 inch.
I usually use bolts to secure the projectors. But these projectors utilize a screw in base. So I made something to cover my big hole. Tomorrow im going to secure the opening with some ABS plastic then cut a hole for the base of the projector.
Then I bonded the abs (after giving it a good sanding) with plastic weld. Here is a comparison of a non modified housing. I will be sticking out maybe 2 inches from a stock housing. Its going to be a close fit on the drivers side.
Tomorrow Ill buy some ABS plastic for the top, then more plastic weld and put more plastic weld at the base.
This is a prototype set. I may change my design for the second set I will be making.
solar67: (2012-02-10 06:21:06)
Re: 7x6 bixenon Projector Retrofit
What kind of price range do you think these will land in? If they work well, I'm sure I'll look into a pair, I've done projector converts on every vehicle I've had, and I always love when they're well done.
P.S. how about blacked out housings?
862sik: (2012-02-10 06:27:49)
Re: 7x6 bixenon Projector Retrofit
The paint, man dont even get me started. Im really not sure what I want to do. LOL. I was thinking of black housing the whole thing, then the front shroud that has the beveled edge leave that chrome. But Its going to be the last thing on my list. Perhaps ill leave it like this and drive on it for a week to test its inegrity, then if someone pays and request a different color arrangment, Ill do it.
As for price, companies who do this professionally charge quite a bit. I seen similar ones that are NOT bixenon go for 350 from this MR2 company. I may put mine in the market for 190-300. It depends on how clean it will look like. Price is still fair because the projectors go for 120 a pair. This current set, its not the cleanest I wanted it to be (prototype). So I wont hike up the price to much. I just dont like that ABS rear end. Just proves to show how anal I am. lol some other people may be like "whatever" lol.
solar67: (2012-02-10 09:33:56)
Re: 7x6 bixenon Projector Retrofit
Lol, I can respect a taste for quality feel. The projector lenses are gonna be expensive either way, and if you save even a bit on the housings, it may help you sell more in the long run with out much compromise on quality, as long as it's well made in the first place.
862sik: (2012-02-10 09:52:57)
Re: 7x6 bixenon Projector Retrofit
Yea I tried to price out the housings. The only way it would be cheaper would be to use glass. It will distort my output a little, and possibly crack....so what's the point. Spend a few more bucks.
As for the rear of the housing, I just pried the living snot out of it and its permanently bonded. Makes me happy. A little bit of silver or black paint will cover the rest cosmetically.
Andrevas: (2012-02-10 23:56:18)
Re: 7x6 bixenon Projector Retrofit
this is much better. though I might have gone with the mini D2S version so people have the option of using genuine Philips/Osram bulbs, not to mention the option of Morimoto's 50W bulbs if you want to be ricockulous.
props to you sir for doing it right. while I usually lean towards OEM components for HID retrofits, looking at some of Morimoto's products, it looks like they make some good stuff actually intended for HID use such as the optics in their projectors and the quality of their bulbs (though I just ignore anything not meant for a true HID bulb socket, which is why I like D2S and similar conversions)
862sik: (2012-02-11 01:30:03)
Re: 7x6 bixenon Projector Retrofit
I personally think the same way as you, oem is the way to go. But I heard so many negitives about the mini d2s and how the mini h1 was superior. I still use a few aftermarket stuff and have used OEM bulbs for my other retros.
Morimoto stuff is really good. I used their bulbs and they are a hair off of alignment, but for the price....its better than cheaper aftermarket, and much better than DDM.
But for the size and what you get out of this projector, I think its perfect and within a reasonable budget.
862sik: (2012-02-17 00:01:55)
Re: 7x6 bixenon Projector Retrofit
I been busy last few days, finally got time to work on these.
I cut a circular piece of ABS plastic and plastic welded it to the base.
Then I grinded down the base with the top. I also let these sit in a bucket of water for 5 minutes to see if there was any leaks. You see a gap in the glue, but its nothing to worry about. I glued the base and then put that cover on top of it. From inside its sealed tight.
Painting them black with krylon fusion for plastic. Unfortunatly its a little bit more gloss than I would like, but its the rear, no one is going to see it.
862sik: (2012-02-17 05:14:38)
Re: 7x6 bixenon Projector Retrofit
Drilled a hole for the projector mount and a small hole for the high beam wires. Its a little bigger, but I did this to minimize any fogging inside the light.
Mounted
Clearence. The yellow stuff is the plastic weld. I made sure that from inside its glued as well
Lens isnt fully on, just testing.
Rear mount
862sik: (2012-02-19 22:58:28)
Re: 7x6 bixenon Projector Retrofit
Im done :-D
But ran into an issue.
The back of my housing hits that metal bar to the right just a bit. I wonder if I should just cut it off. It seems to support the anchor point where the motor makes the light go up and down. I wonder if I should.
Careless: (2012-02-19 23:11:19)
Re: 7x6 bixenon Projector Retrofit
i would slot it. and then paint it. as long as you cut it nice- it will be worth the time saved in trying to do something else to make it fit and it will look legit.
either way, what else can you do to make it fit? it's most likely your only solution…
nice work! you can also hit the krylon gloss black with 800 grit sandpaper to dull it up or spray some regular satin or flat black paint over it, since it's already bonded to the plastic.
862sik: (2012-02-20 01:03:59)
Re: 7x6 bixenon Projector Retrofit
I wouldnt mind cutting it as long as it is still strong. It will make room for my next project.... :-D for the lights.
I just dont want to take apart my housing again lol. I can make a clean cut though, really clean. I use my mitre saw lol.
DeleriousZ: (2012-02-20 02:28:33)
Re: 7x6 bixenon Projector Retrofit
pretty slick, can't wait to see pics of the cutoff lines once installed!
862sik: (2012-02-20 07:16:07)
Re: 7x6 bixenon Projector Retrofit
Ill cut them a little tomorrow.
I was searching the net, I wanted to show how some people mount projectors in these housings.
[archived image: 6164524607_c4cc3cfdc3_b.jpg]
862sik: (2012-02-23 05:02:05)
Re: 7x6 bixenon Projector Retrofit
Well ran into an issue trying to fit this into the z. The housing itself is a tad to big for our car. The thickness of the plastic lens and the housing is a little thicker than the bracket that holds the housing in place.
The only way to get it on nicely is to be able to take off the ring that holds the factory housing and put it on without bending…thats not going to happen lol.
I got another set of housings, the glass lens. Those should fit without issue.
On a good note, I put these in a buddies s13, fits perfectly without cutting. He was amazed because all retrofits involve cutting the metal. His car rides like a rock and its a great car to test the durability of my design.
bettzysdaddy: (2012-02-23 19:16:34)
Re: 7x6 bixenon Projector Retrofit
I'm buying back my cousin's mini D2S projectors I got from TRS I originally sold him. I found Pilot brand H4 conversion kit on Amazon, and I'll try it with the mini D2S setup.
I had purchased an ebay set and it has glass lenses. I'm gonna toss them and try the Pilot set to see if I can get my retrofit going.
862sik: (2012-02-23 19:27:19)
Re: 7x6 bixenon Projector Retrofit
I'm actually selling one set of pilots. I haven't sold it on here yet.
http://www.hidplanet.com/forums/showthr … m-housings
They have a small surface scratch…if u want em
PulseCode: (2012-02-24 21:40:08)
Re: 7x6 bixenon Projector Retrofit
Very nice work, Sir. Even though they are not intended to be used as fogs, I went with the Stage III FX-R's from TRS in the fog position.
I sealed the housings with GOOP adhesive and finished them in black. I am running 55W ballasts in them- The light output is stunning.
viewtopic.php?f=4&t=28869&p=328684&hilit=Retrofit+ FXR+fogs#p328684
862sik: (2012-02-25 02:28:17)
Re: 7x6 bixenon Projector Retrofit
Thanks man.
Yea those projectors rock. I have a set of them in my van, and I put a set in my friends car. Good value for the money.
862sik: (2012-03-02 09:41:32)
Re: 7x6 bixenon Projector Retrofit
Ran these lihts in my friends s13 that had a rock hard suspension. Ran into a small issue with the Hoke I Driller forbthe high beam. Easy fix. And.....it didn't fall apart lol.
I also fixed my oven. So finally get to start making a few sets.
862sik: (2012-03-04 03:36:07)
Re: 7x6 bixenon Projector Retrofit
Prototype number 2!
Since I had a clearence issue, I knew there had to be another way to secure the projector. So decided to work on this glass set today (and it fits perfectly by the way). These are glass lenses and there were a BIOTCH to open. The plastic lens opened at 275 degrees for 7 min. These ones was 375 for 20 minutes!!! The housing actually warped a little bit, which helped pry off the glue…but when it cooled down it formed back to normal.
I now have no more issue with that bar behind the light. Makes me happy.
Got some 2 pvc pipe, you will see why later. As you can see I cut the rear of the housing out, and cut on the sides to allow the projector to sit correctly and sit lower.
Rear view
This is how it will sit. On top of that pvc im putting a ABS cover just like my first attempt. That way the projector has something to mount to. The pvc will be plastic welded to the housing.
Projector clearence, JUST enough
Here is how the PVC sits. Almost a perfect fit.
JN210: (2012-03-05 04:15:24)
Re: 7x6 bixenon Projector Retrofit. **Prototype #2 on page
nice dude, cant wait to see my kouki lights [archived image: wink.png]
862sik: (2012-03-06 09:38:34)
Re: 7x6 bixenon Projector Retrofit. **Prototype #2 on page
Unit put together. I finally bought some low gloss paint instead of gloss, looks much better. These units had city lights, I took them out and routed the wiring for the high beam through them. I also like these housings because they have built in vents, saves me troubles later.
Now this will definitly fit in the z lol.
Greasedmonkey: (2012-03-07 07:41:55)
Re: 7x6 bixenon Projector Retrofit. **Prototype #2 on page
Im in to see how these turn out.
862sik: (2012-03-09 06:59:08)
Re: 7x6 bixenon Projector Retrofit. **Prototype #2 on page
Been occupied with another car latley, but finally gave these puppies a chance to dry. I sealed them up with silicone because the old rubber stuff was hopeless.
Ven: (2012-03-13 04:58:00)
Re: 7x6 bixenon Projector Retrofit. **Prototype #2 on page
Yes, I'd like to see the kouki lights.
862sik: (2012-03-13 08:48:43)
Re: 7x6 bixenon Projector Retrofit. **Prototype #2 on page
[quote]Ven wrote:
nice dude, cant wait to see my kouki lights [archived image: wink.png]
Yes, I'd like to see the kouki lights.
In progress… :slurp Going shopping for supplies in the morning :-D
edicer2: (2012-03-13 13:19:32)
Re: 7x6 bixenon Projector Retrofit. **Prototype #2 on page
how well do those work with the headlights flipped down or is the cut off line to low to do that??
regardless v2 looks great!
862sik: (2012-03-13 19:38:06)
Re: 7x6 bixenon Projector Retrofit. **Prototype #2 on page
Not great unfortunately. The design if the projector in the way they emit light sucks when in sleepy mode. All foreground is gone, all you see is some light at the cutoff line.
I'm my first design I tried to mount the projector higher and still no luck.
But with cool projectors, I'd like to show them off [archived image: wink.png]
RocklinMike300zx: (2012-03-14 22:39:13)
Re: 7x6 bixenon Projector Retrofit. **Prototype #2 on page
Damn, lookin good man. I may have to sign up for a set this summer if you're down.
862sik: (2012-03-16 08:23:35)
Re: 7x6 bixenon Projector Retrofit. **Prototype #2 on page
Man im always down!
Well the prototype #2 glass is going great. My friend had an issue with very little water getting in. So I played with the bulb and the little rubber gromet. It should fit snugly to prevent water from getting in. It shouldnt be an issue in our z because our lights sit flat.
862sik: (2012-03-16 08:28:01)
Re: 7x6 bixenon Projector Retrofit. **Prototype #2 on page
[quote]Ven wrote:
nice dude, cant wait to see my kouki lights [archived image: wink.png]
Yes, I'd like to see the kouki lights.
See what? :-D
So for J18199, I decided to use this setup. He has a pretty agressive looking car with lots of angles. I wanted to go for a sharp look, and this shroud matched perfectly. This is the apollo shroud.
In the last picture I used semi gloss paint, I personally dont like it. If you look closely you will see that I just painted over the messed up chrome. I just wanted to paint it black to see how it would look. I picked up some satin paint, and paint stripper to clean up the headlight last night.
edicer2: (2012-03-16 13:08:01)
Re: 7x6 bixenon Projector Retrofit. **Prototype #2 on page
what are you going to use for a clear lense?
862sik: (2012-03-16 17:45:42)
Re: 7x6 bixenon Projector Retrofit. **Prototype #2 on page
Acrylic. But I'm going to go a little thicker than normal, and instead of a thin piece of plastic I was going to make it look a little better Kind of hard to explain.
I wanted to vacuum form the lens, but I don't have an oven for it. So I was going to get a piece of acrylic and make "legs" behind it so that it sits in the groove of the headlight. If I get a standard piece of acrylic and just slap it on the glue would be all spread out and look like crap.
edicer2: (2012-03-16 18:39:24)
Re: 7x6 bixenon Projector Retrofit. **Prototype #2 on page
yeah i hear ya ill have to keep a a eye on what you end up doing then.
862sik: (2012-03-16 19:13:57)
Re: 7x6 bixenon Projector Retrofit. **Prototype #2 on page
Haha you have the zenki front end, what you worried about lol
JN210: (2012-03-16 19:51:32)
Re: 7x6 bixenon Projector Retrofit. **Prototype #2 on page
I think he means for his other car, its a 87 haha.
edicer2: (2012-03-16 23:26:28)
^^ bingo.....might want to do this to both z's if they come out well! (87t and a 86na)
Andrevas: (2012-03-17 11:02:07)
if you were crazy you'd grind/polish the fluting out of the glass of the kouki lenses so you don't have to do any lame shit with acrylic to try and make that work :nanan?re
good reference on lens polishing: http://forums.turbobricks.com/showthread.php?t=131958
-Strike-: (2012-03-17 12:10:03)
Glass polishing is a pain in the ass lol. I just tried that with my headlight lenses to get rid of the pits. After wetsanding with coarse grit 80-120, working all the way up to 2000 grit, it was still cloudy. Had to buy some cerium oxide powder to polish the glass afterwards, as regular compounds won't touch the harness of glass, Came out decent, but still not close much better than it was haha. Just way too many hours of work.
Andrevas: (2012-03-18 02:16:43)
yeah, it's a bitch and takes a lot of work and especially if you're doing something as insane as polishing the fluting out to clear (you'll probably blow up your first one or two lenses doing it) but I think the results are a lot nicer looking.
862sik: (2012-03-18 03:15:46)
Ah gotcha.
862sik: (2012-03-18 03:16:48)
I wouldnt mind, but with the glass…it takes a little bit away from the output. I really dont want to be grinding glass for a long time lol.
He had it easier, and just keeping the cutting in one spot. Since I have a shroud on mine that I would like to show off it would be more work to do the whole lens.
Sharpen047: (2012-03-18 17:22:53)
I wondered how it would look if i painted the chrome black on the shroud and stock light. I may want to do that since my car is also black.
862sik: (2012-03-18 18:51:19)
It may look cool…but you will loose lots of light with the halogen. But why would you want to remplace your projectors for stock?
Sharpen047: (2012-03-19 20:59:11)
I put projectors in stock lights. No halogen.
862sik: (2012-03-19 21:23:04)
OH lol I thought you meant get stock housings, paint the inside black and put them back on. lol :lol:
Me personally I like a little bit of "style" and contrast. Just being black doesnt look right IMO. You can maint your housing black, and leave the shroud chrome. There are endless possibilities.
Today I will be painting it black, but I want to try and get started on the lens cover. Hopefully it turns out good.
862sik: (2012-03-20 07:49:54)
I love satin black paint! I also painted the sides of the shroud to look more like a floating shroud.
edicer2: (2012-03-20 13:31:20)
looking good!! interested in see how the acrylic comes out.
bettzysdaddy: (2012-03-21 02:58:42)
Re: 7x6 bixenon Projector Retrofit. **Prototype #2 on page
What did you use to hold the projector in place where you insert the bulb? A washer? plastic? metal?
862sik: (2012-03-21 09:06:54)
Magic!
lol. I used a water that basically sandwiches the projector and the headlight together. It comes with the projector when you purchase it from the company.
DeleriousZ: (2012-03-21 15:31:22)
So when are direct replacement housings for the kouki going to be available? [archived image: wink.png]
862sik: (2012-03-22 03:26:10)
As soon as I figure out this acrylic. I been playing with it and trying to get a perfect edge. I made a rectangular box to match the old headlight. Basically 1 high, and the width of the headlight. I been doing so many alarm installs for friends that I havent had time to really work on it. I should have something by monday.
As for replacment housings being avalible, I can always start them as long as I get a down payment for supplies…possibly a set of housings if you have them, if not I have to go to the yard and pull them myself.
Ven: (2012-03-22 20:20:44)
I assume this is the kouki shroud right? If you want to be fancy, you could fit a nice thin white led strip across the top of the shroud so when the lights are down people could flip the leds on (maybe wired to the foglight switch). I'd think it'd look cool.
Probably something like this
[archived image: 09-06-12-vaistech-vline-led-lights-4.jpg]
862sik: (2012-03-22 20:44:32)
[quote]Ven wrote:
I love satin black paint! I also painted the sides of the shroud to look more like a floating shroud.
I assume this is the kouki shroud right? If you want to be fancy, you could fit a nice thin white led strip across the top of the shroud so when the lights are down people could flip the leds on (maybe wired to the foglight switch). I'd think it'd look cool.
Probably something like this
[archived image: 09-06-12-vaistech-vline-led-lights-4.jpg]
Thanks for the suggestion. If the person who is buying it wants it....then I will do it. I personally don't like them, but these are not my lights hah
Ven: (2012-03-23 02:04:04)
[quote]862sik wrote: [quote=Ven]
I love satin black paint! I also painted the sides of the shroud to look more like a floating shroud.
I assume this is the kouki shroud right? If you want to be fancy, you could fit a nice thin white led strip across the top of the shroud so when the lights are down people could flip the leds on (maybe wired to the foglight switch). I'd think it'd look cool.
Probably something like this
[archived image: 09-06-12-vaistech-vline-led-lights-4.jpg]
Thanks for the suggestion. If the person who is buying it wants it....then I will do it. I personally don't like them, but these are not my lights hah
Something to keep in mind when I purchase mine LOL 8)
RocklinMike300zx: (2012-03-24 00:01:28)
That is a really good idea though. I could see perhaps modifying the headlight bucket or something to fit in some LED strips and have them wired to the foglights or use a custom switch to turn them on when the buckets are down. Maybe I'll talk to my buddy about making something to that effect.
862sik: (2012-03-24 07:56:26)
Yeah, anything is possible with electronics. I install alarms and stuff, and I can make anything happen =)
862sik: (2012-03-24 22:08:15)
Well I finally had time to put together these lenses and let them dry (after countless failed trials). I SHOUld of made them maybe a 1/8 higher to take up the gap in the top and bottom, but I dont think it will affect anything. I also decided to router the edges just a little bit to make it look better. I think it looks great. It mimics the factory glass. I will probably push the whole lens upwards so that there wont be much gap up top.
If I decide to, I may paint the inner side of this lens black to further cover everything. After im done ill flame polish the corners to get rid of that "white opaqe" look where the lens meets eachother.
Tell me what you guys think
edicer2: (2012-03-24 22:12:12)
Looks fantastic man! Will that fit between the bumper looks like it sticks our really far but i guess i havent looked at the factory headlights to see how large the glass part is.
862sik: (2012-03-24 22:24:05)
yeah it SHOULD fit in the bumper, Its probably about 1/8 less than the factory headlight, depth wise.
edicer2: (2012-03-24 22:33:19)
oh ok gotcha im looking forward to seeing it all mounted up and finished looks great though!
862sik: (2012-03-25 04:14:24)
Hehe Ironically, I dont have a car to mount these to lol. :nanan?re
I did some flame polishing today to get rid of the opaque look on the sides.
My work isnt perfect, had a few bubbles under the acrylic. I hate those. But looking at the lens as a whole unit, its not that bad at all.
Before flame polishing.
edicer2: (2012-03-25 15:23:05)
looking great so far!
862sik: (2012-03-26 07:36:16)
I got bored, more pictures of the shroud after I painted it. Its not perfect, but its darn close
862sik: (2012-03-29 03:29:05)
I got some nicer pics of one of the headlight lens.
They are not perfect, but they are solid. :-)
JN210: (2012-03-29 04:36:12)
sooo SICK!
much better alternitive to fixing my cracked headlight than getting an OEM replacement.
edicer2: (2012-03-29 04:58:51)
Lets seem some installed pics!!!
862sik: (2012-03-29 05:20:29)
Cant find anyone local with the kouki front end lol.
JN210: (2012-03-29 06:32:02)
If he cant find anyone…then its going to have to wait until May [archived image: frown.png]
edicer2: (2012-03-29 13:46:52)
damn! was looking forward to seeing them!
DeleriousZ: (2012-03-29 15:20:18)
I can test fit them if you want to ship them up the coast lol
Ven: (2012-03-29 16:12:36)
Whose ever lights these are, get the LED strip put in!!! lol
JN210: (2012-03-30 03:54:22)
Mine, and idk…I think itd be a bit much with all thats already going on with my car…is an interesting idea though.
862sik: (2012-03-31 06:42:25)
Didnt have time to put the sealant on today. Got to determine if I need to vent this.
Just a little bit of imagination!
edicer2: (2012-03-31 06:52:34)
looks great!!!
Demon Z: (2012-04-20 17:06:59)
Bump??
JN210: (2012-04-20 18:03:11)
I havnt got the car back yet [archived image: frown.png] May 5th I will have it and im going to pay for em the week before and that way the car and lights will be together in the same place around the same time, I will be sure to put pics up when that time comes!
Ven: (2012-04-20 22:07:34)
Good, then we can photoshop them with the LEDs in them. :nanan?re
862sik: (2012-05-10 05:49:04)
Though im happy with the lens, im not to happy about the glue inside. Its a little clumpy,what do you think.
Im using a glue that honda uses, its not butyl. Its stronger, and holds WAY better than butyl. If I were to put butyl on here, the lens would have a tendency to come off in the heat. With this stuff, its strong as hell (also pricy) but not messy.
I also had to re-modify the rear of the unit so that the projector will mount correctly. Now it will be easier for someone to adjust the rotation if they had to. Also I incoorporated 2 air vents "just incase". I was contemplating on this for a whole week on how to vent these. Some people say dont, some say yes…So I said yeup.
with the bracket on.
See, through the front of the lens, the seam is almost invisible.
see..I dont like the globy glue
Look it has a very small ghost ha-lo effect lol.
Ven: (2012-05-11 03:35:36)
Dunno if this would work but if there was an inner border between the lense and backing to cover the glue then that might work. So for instance if the was a thin piece of metal drilled to the lense and then bent (say maybe 45°) then the space behind it would have the glue. Think something like __/. The glue would be where the period is.
On the bottom the metal might cover the bottom of the lense assembly (not the lense itself) depending on the angle of the bend. The top would follow the same rules except a thin set of LEDs would cover anything. 8) The sides would pose no problem.
G-E: (2012-05-11 06:30:55)
if you go through the trouble of adding metal, why not have the metal bent to be the actual lens retainer like a spring-clip on a gm air filter box?
surely a removable lens would be even better? think chips/scratches..
Ven: (2012-05-11 06:51:27)
The lense inside? How would that get any chips or scratches if it's in the plexi box?
If anyone was concerned about the plexi (or whatever material it is) housing getting chipped/scratched then they could easily opt for the 3M clear wrap to cover it. I'm sure the area needed to cover the front of the housings for both lights wouldn't cost that much.
G-E: (2012-05-11 08:44:11)
yes I meant the plexi outer "lens", much easier if it's a clip on, and even cleaner for the glue situation… make it a sandwich clamp with a couple small springs on the side pulling them shut and done!
862sik: (2012-05-11 22:08:40)
[quote]G-E wrote:
The lense inside? How would that get any chips or scratches if it's in the plexi box?
If anyone was concerned about the plexi (or whatever material it is) housing getting chipped/scratched then they could easily opt for the 3M clear wrap to cover it. I'm sure the area needed to cover the front of the housings for both lights wouldn't cost that much.yes I meant the plexi outer "lens", much easier if it's a clip on, and even cleaner for the glue situation… make it a sandwich clamp with a couple small springs on the side pulling them shut and done!
thats way to much work, less reliability, whole lots of fabrication, and probably ugly. This glue is still removable. Just some heat and it will come off, same as the oem in hondas, nissans etc.
This plexi I choose is thicker, but anything will have a tendency to get chipped. But if you think about it, glass is more prone to this because they will shatter. Plastic wont. If I were to guess, maybe about 6 years you may need to wetsand and buff these down. But put a layer of protection every month or 2, and it will last a LONG time.
There are people who did what I did but with much thinner lenses, and 3 years to date they only have a few nicks which is common.
stufferton: (2012-05-12 01:12:55)
Any idea how well these will illuminate the road using the 'Sleepy Eye' look on the late model nose? Are they a short enough profile that more than half of the bulb can peek out? Or not a clue?
862sik: (2012-05-12 05:35:31)
I played with the idea by finding out exactly where the bumper covers the light and used black tape. Lighting sucks. Its the design of the projector and it needs to use the lens of the projector to get full light. When I did it, all you saw was a cutoff line. No foreground at all.
PulseCode: (2012-05-15 04:22:25)
[quote]862sik wrote:
Any idea how well these will illuminate the road using the 'Sleepy Eye' look on the late model nose? Are they a short enough profile that more than half of the bulb can peek out? Or not a clue?
I played with the idea by finding out exactly where the bumper covers the light and used black tape. Lighting sucks. Its the design of the projector and it needs to use the lens of the projector to get full light. When I did it, all you saw was a cutoff line. No foreground at all.
Great work man. Keep up the quest. If you don't like seeing the glue and you decide to make additional sets you could
always use painters' tape to mask up the center portion of the headlight housing face and spray paint the perimeter (trim)
flat black. Do this from the INSIDE first, give it plenty of time to dry and the glue will stick fine to it. For the '87+ guys.
viewtopic.php?f=4&t=28869&hilit=projector
862sik: (2012-05-15 05:45:18)
[quote]PulseCode wrote: [quote=862sik]
Then how would you take out the tape after you put the lens on? lol.
I havent had time, but it should be easy to make it less noticable. But in the future I will probably find a metal tube that I can load a bunch of this sealant in. Heat the whole thing up, then spread it evenly and uniformly. It should be pretty clean.
But, I am not sure if I will do this for anyone anymore lol. Maybe just provide the lens.
Ven: (2012-05-17 18:09:51)
The glue probably won't even be noticeable anyway once installed (can't believe their aren't any kouki Z31 owners in your area lol). But you have to make at least 1 more set for me. LOL :twisted:
It'd look especially badass with Q45 projectors.
edicer2: (2012-05-17 18:38:08)
DUDE when are these getting installed in the car!!!
NissanXRMA: (2012-05-18 03:41:01)
DUDE when are you going to finish the LED tails…
edicer2: (2012-05-18 04:31:08)
[quote]NissanXRMA wrote:
DUDE when are these getting installed in the car!!!
DUDE when are you going to finish the LED tails…
oh snap! ha when the gray car is done! Then its full out led soldering time!
862sik: (2012-05-30 06:04:30)
I have been so busy, got to play with one of them over the weekend. Im not super proud, but the glue looks much better.
Ven: (2012-05-30 21:48:40)
Once installed and it being recessed in the light cavity, no one is gonna be looking at glue. Looks good.
Datsunking1: (2012-06-05 15:17:12)
^^ this.
Looks awesome man! Keep up the good work!
Richard_85ZXT: (2012-06-08 02:38:19)
For future you can tape off the inside and paint the edges black so no one sees any glue, and for some reason black paint inside looks very clean. I learned that from an old kit car building show on speed channel look up kit an autobody experience and they build a porsche in that they show what I mean.
862sik: (2012-06-08 19:50:42)
What you mean? If I get glue on top of the tape, it wont come off because the glue is strong lol
Richard_85ZXT: (2012-06-08 21:56:17)
Lol yeah not gluing while tape on there, tape off all but like 1/4 or 1/2 inch depending on how you want it to look or how much glue will be on there, paint inside black, remove tape so the border will be black almost like a picture frame, but any shape you want and the glue on the edges is then hidden by the "frame", I'll try to find a video of what I mean at somepoint but hopefully that gives a better explaination.
862sik: (2012-06-08 22:04:24)
I see what your saying. But the glue is more of a semigloss black. Thats why it shows up on top of my low gloss black paint. I can live with it I think....lol
Richard_85ZXT: (2012-06-08 22:26:07)
Yeah, I just figured for future reference it would cover up for a nice clean look and less time spent trying to make it look better. I'm looking at something similar myself, but too many other things to take care of first.
here's a pic of more or less what that would look like, and under the black ring around the lens would be the glue.
Racinjitter: (2012-06-12 02:02:00)
Pretty cool stuff. Way to step it up. I guess I will have to install my set finally.
862sik: (2012-06-12 15:50:38)
Ah ic what your saying there. I played with the look of painting the border black, it looked to tackey and to "ebay". id rather live with the glue seam. But the glue seam is much better looking now.
Ven: (2012-07-13 13:39:04)
What's new with this? Someone install it yet?
862sik: (2012-07-13 17:01:29)
Im awaiting payment to send them. They are finished, and I tested them under water to make sure that there is no leaks. I also sanded down and polished the lens to take out the scratches I made. It looks great, hope he is happy.
In the future I am not sure if Ill do this because it takes quite a bit of time. I will probably supply the lenses, but thats about it. I had lots of time when I didnt have a job, but now that isnt the case might do another set…who knows =). But we will see once he recieves it how he likes them, he can judge the quality and give me feedback. I personally think they will be bad ass.
Ven: (2012-07-13 21:20:55)
[quote]862sik wrote:
Well when I order MY set it's cool if you take your time. :twisted:
and yes, I'm sure they'll look badass. Probably even more so with an LED strip in it. 8)
I await the pictures of installation.
edwin86z: (2012-07-17 10:54:19)
Hey guys,
I have been working with a production factory that actually makes HID projectors. We have been working on designs for about a month now, but hopefully the efforts will be worth it.
The main issues for Z31 projector retrofits into the H6054 (84-86) housings are the physical size of the projectors themselves. Most bi-xenon projectors are about 5" in length. The most common "upgrade" for the H6054 is of course the eBay diamond cut reflector housings that convert sealed beam to H4 bulbs.
Many aftermarket projectors are made to fit directly into H4 housings, but as far as the aftermarket H6054 housings are concerned, projectors are too long for the front lens to fit back on.
Even if you were to modify the housings to let the projector sit deeper in the housing, you run into the problem for the flip up lights, with the back of the housing hitting the arm that moves the bucket up an down (the OP ran into this as well). This is especially true with D2S projectors, as I have cracked my setup when attempting this myself.
What we have developed is a bi-xenon projector that is a total of 4" in length. The projector uses a H1 HID bulb. The size of the projector will allow it to fit perfectly in the housing, and with the use of the H1 bulb, there will be plenty of room behind the housings to allow proper use of the flip up lights. The projector is much shorter than the common projector retrofits, and provides a simple installation.
To keep costs low, the set will be sold as a retrofit kit. I would recommend purchasing the cost-effective housings on eBay. That way you can pick your own style housings (I personally prefer the plain housings with no extra lights or halos, seen here: http://www.ebay.com/itm/H6054-7X6-H4…d415e9&vxp=mtr).
All you would need to do is bake the housings at 220°F for 8 minutes and pry the lens off (throw it back in the oven if it cools down, don't break the glass!). Remove all the metal hardware from the housing (2 screws that hold on the H4 bulb clip and metal cap, comes right out), then drill a small hole below the opening for the high beam wire. Install the projectors and reseal the housings.
Once the projectors arrive, I will have a full install guide, as well as beam shots with it on my Z. Hopefully I can keep prices low, around $100.
Also wanted to fill you guys in on some research, there is a type of projector retrofit already available that will fit into the H4 housings without modification (other than baking and removing the glass). They are seen here: http://www.ebay.com/itm/AngelEye-Sup…d45935&vxp=mtr. The look nice and all, BUT… there were a few things I didn't like. One issue I did see was the bulb. It uses a specially made HID bulb, not a common size. You can get replacement bulbs from the seller, but they charge a lot for a low quality bulb. Also, after much digging, I was able to find the action shots. The beam output and cutoff is HORRIBLE! I would not suggest going this route. Even though the output is better than using a H4 HID kit in reflector housings, I would still not get it.
That is what led me to having the better ones made. Sorry for the long read, I will have an update as soon as they are finished making them!
-Edwin :super
edwin86z: (2012-07-17 14:41:59)
Btw, here's how the setup had come out with the old projectors (driver side is projector, passenger side is old and worn out ebay H4 housing). As stated in the last post, this is the common 5" long projector retrofit with the D2S bulbs. While it works great, I can't put them down, otherwise the swing arm will crack the back of the housing (again!).
I can't wait until the new projectors are done!
862sik: (2012-07-17 23:12:36)
Are you apart of the company that has the pegasus units from norcalmr2? Cause if it is, I dont mean to be blunt, but the output sucks ass. lol.
The bixenon projector I used fit, but of course a mount has to be made…which dont take to long.
edwin86z: (2012-07-18 03:34:48)
I have nothing to do with the pegasus units, nor am I part of a company that makes projectors. I have just been in communication with a company that develops projectors, and have convinced them to develop a system to work with the popular H6054 housings.
I honestly don't know how well this will come out, but I will post beam shots as soon as I can get them.
862sik: (2012-07-18 17:15:24)
Its interesting in how you convinced them tto make a prototype. It takes time and money to make prototypes because most of the time they have to be improved, and to be around 100$ id be concerned about the width and the focus of these projectors. But you never know =).
Thats why I used the morimoto projectors. They are nice and compact, plus they are bixenon. There is a pair that uses d2s but they were a tad longer, and even though I like OEM bulbs, these morimoto bulbs are pretty darn good.
edwin86z: (2012-07-18 23:41:50)
I was surprised too! I also like the morimotos, but they are a tad long to fit in the housing without modification, and I was looking for a better solution.
They were actally working on the shorter 4" H1 projector before I contacted them, but they were not active with the project as they were working on something else. After contacting them, they started it back up and finished the design. They are now working on the shroud. They said they can have a new mold custom made for me, but I could not justify the $16,200 price tag… I told them I would take the mold they were working one, hopefully it will fit with a couple of cuts to shape.
Again, I don't know how well they will work, but the only way to find out is to wait for them. To come in!
alexbre00: (2012-07-19 04:58:21)
In need of 87+ projectors!!!,. Great job!! Keep up the good work so happy z31's are getting love
JN210: (2012-07-20 08:57:42)
Bump, big suprise comin soon guys, keep posted [archived image: wink.png]
JN210: (2012-07-25 07:42:55)
So im trying to remove my headlights so as soon as ive got these I can put them in, anyone have the best way to remove them with step by step instructions? because the book doesnt really help…how the hell am I suppose to get the lid off with the fender in the way!?! lol....gay....
Richard_85ZXT: (2012-07-25 08:40:02)
Take the whole headlight bucket out, few bolts behind the headlight cover and if I remember right 87-89 has a few on the bottom of the bucket you get at from under the car, but it's been a while so I might be wrong.
JN210: (2012-07-25 08:47:44)
Found out how to and took me 20 minutes or so to get em both out, was easy as pie. I was just doing it wrong lol. Lights are out and waiting on my projectors now [archived image: wink.png] pics will be up as soon as they arrive!
Ven: (2012-07-29 04:58:31)
Just a few picture requests.
daytime pictures
1.) Picture from the front with the lights down & Off
2.) Picture from the front with lights down & On (if you have the mod)
3.) Picture from the front with the lights Up & On
night/evening pictures
4.) Picture of the car facing a wall with lights down & On
5.) Picture of the car facing a wall with lights Up & On
thanks
JN210: (2012-07-29 21:24:19)
np, can do, lights should be installed tomorrow evening or so, so I should have pics up here by the end of the day!
862sik: (2012-07-29 22:13:22)
[quote]J18199 wrote:
Just a few picture requests.
daytime pictures
1.) Picture from the front with the lights down & Off
2.) Picture from the front with lights down & On (if you have the mod)
3.) Picture from the front with the lights Up & On
night/evening pictures
4.) Picture of the car facing a wall with lights down & On
5.) Picture of the car facing a wall with lights Up & On
thanks
np, can do, lights should be installed tomorrow evening or so, so I should have pics up here by the end of the day!
Im curious as well but not in the looks but in how much of the glue you will see when its installed. The majority should be hidden by the trim around the light. 8)
JN210: (2012-07-30 18:56:08)
well, ive got the lights but the outter ring around the headlights broke off and needs to be glued back on, so its going to be a few more days…
862sik: (2012-07-30 19:48:40)
....yeah im not happy about that. Not happy at all.
PulseCode: (2012-07-31 02:55:13)
[quote]862sik wrote:
well, ive got the lights but the outter ring around the headlights broke off and needs to be glued back on, so its going to be a few more days…
....yeah im not happy about that. Not happy at all.
After the amount of labor that has gone into this project- please… Don't be discouraged. Everything
WORTHWHILE on the Z31 takes considerable time and effort. From the custom whaletail that I have
been working on, to the complete white LED instrumentation conversion, to the tool storage area fiberglass
subwoofer enclosure- each section has its' own set of problems and rewards for overcoming the inherent setbacks.
YOU are enriching the Z31 community. Thank you for the effort you've expended so far and KEEP UP THE FINE WORK!
862sik: (2012-07-31 05:53:10)
[quote]PulseCode wrote: [quote=862sik]
well, ive got the lights but the outter ring around the headlights broke off and needs to be glued back on, so its going to be a few more days…
....yeah im not happy about that. Not happy at all.
After the amount of labor that has gone into this project- please… Don't be discouraged. Everything
WORTHWHILE on the Z31 takes considerable time and effort. From the custom whaletail that I have
been working on, to the complete white LED instrumentation conversion, to the tool storage area fiberglass
subwoofer enclosure- each section has its' own set of problems and rewards for overcoming the inherent setbacks.
YOU are enriching the Z31 community. Thank you for the effort you've expended so far and KEEP UP THE FINE WORK!
Thanks, its just depressing that the first thing I came up for the z community is something that got messed up during shipping LOL.
Well, things happen. Learn from them =)
JN210: (2012-07-31 17:56:28)
Well, I wasnt about to let it slow me down, I got ambitious and excited about it, so I popped em in the oven and used a 2 part epoxy called ATACS, awesome stuff if you want shit to STAY lol. these lights are awesome.. bright as hell lol…my dad and I were able to make shadows on the trees about a quarter mile away with the lights on high beam LOL.
yes, ik the car is dirty…its been awhile and ive been busy
[archived image: headlight1.jpg]
[archived image: headlight2.jpg]
[archived image: headlight3.jpg]
[archived image: headlight4.jpg]
[archived image: headlight5.jpg]
[archived image: headlight6.jpg]
[archived image: headlight7.jpg]
[archived image: headlight8.jpg]
[archived image: headlight9.jpg]
[archived image: headlight10.jpg]
DeleriousZ: (2012-07-31 18:11:58)
beautiful cutoff line. I like that!!
JN210: (2012-07-31 19:50:26)
Im excited to drive it tonight to see how bright it really is lol…its pretty crazy bright. I love it!
biggz31: (2012-07-31 20:09:16)
it looks very good, very good job, it look like transformers car
862sik: (2012-07-31 20:38:43)
Wow they look great on the car. This is the first time I get to see them mounted!
For that epoxy, I didnt want to use it. I wanted to use the sealant I use because its a OEM sealant, and its harder than standard butyl because it has an adhesive in it. I want the ability to remove it if I had to. Did the acrylic distort or discolor when you put it in the oven? But id like to know more about that expoxy for future projects,.
But Id like to see a closeup on how you guys glued it…did you guys remove all the old stuff? Can you also show me a close up of the light so I can see just how much of the borders actually show?
How is the fitment of the lenses, did you have any clearence issues? How do you like the custom lens?
As for the picture of the cutoff, the car being further away will show it better.
Im glad you are excited. I am as well.
Ven: (2012-07-31 20:46:46)
I Want!
Looks very nice. Cutoff and all.
And yall were worried about glue showing. From that close shot in front of the car it looks perfectly fine. No one is looking at it an inch away from the lense.
Now to photoshop one of those pictures with an LED strip in the top of the lense. :twisted:
JN210: (2012-07-31 23:11:09)
acrylic is perfectly fine, baked it for like…15 mins or so at 170* then it peeled right apart. any of the old glue you used on the plastic silver housing around it was gone, no sign of anything…as for the clips on the back of the silver housing, one was broke / missing, did you break it before? It wasnt rattling around inside it.
as for the borders, I just made them even all around, and its perfectly alligned with the road and they are pointing straight. no fitment issues, went right in after putting the mounting bracket on it. no clearance issues....I should get a pic of the lights shining on the trees across the road…heh, I did some adjustments and they arent aimed as high anymore.
Now, ATACS, is an AMAZING epoxy, two part as ive said, and they use it to fix aircraft, and with aircraft, it has to be strong. So for any future projects, get it alligned how you see fit, and then use that (you may not be able to get it at any store, ebay im sure has it) ATACS will forever bond it in whatever way you want. wont ever have to worry about anything falling apart.
862sik: (2012-07-31 23:22:40)
[quote]J18199 wrote:
Wow they look great on the car. This is the first time I get to see them mounted!
For that epoxy, I didnt want to use it. I wanted to use the sealant I use because its a OEM sealant, and its harder than standard butyl because it has an adhesive in it. I want the ability to remove it if I had to. Did the acrylic distort or discolor when you put it in the oven? But id like to know more about that expoxy for future projects,.
But Id like to see a closeup on how you guys glued it…did you guys remove all the old stuff? Can you also show me a close up of the light so I can see just how much of the borders actually show?
How is the fitment of the lenses, did you have any clearence issues? How do you like the custom lens?
As for the picture of the cutoff, the car being further away will show it better.
Im glad you are excited. I am as well.
acrylic is perfectly fine, baked it for like…15 mins or so at 170* then it peeled right apart. any of the old glue you used on the plastic silver housing around it was gone, no sign of anything…as for the clips on the back of the silver housing, one was broke / missing, did you break it before? It wasnt rattling around inside it.
as for the borders, I just made them even all around, and its perfectly alligned with the road and they are pointing straight. no fitment issues, went right in after putting the mounting bracket on it. no clearance issues....I should get a pic of the lights shining on the trees across the road…heh, I did some adjustments and they arent aimed as high anymore.
Now, ATACS, is an AMAZING epoxy, two part as ive said, and they use it to fix aircraft, and with aircraft, it has to be strong. So for any future projects, get it alligned how you see fit, and then use that (you may not be able to get it at any store, ebay im sure has it) ATACS will forever bond it in whatever way you want. wont ever have to worry about anything falling apart.
What clips are you talking about? Are you talking about the OEM bulb holder for the oem light? If so then yes I cut them out to make room so that the projector sits nicely. I had it in there with the OEM mount but it would make it near impossible to align them and tighten them back down, and at the same time create a seal so that water wouldnt get in. So the way that I mounted everything was the only way I can do it. But when you said one was broke....I know I didnt do both of them exactly the same. One was a little different than the other. It wasnt broke, it was modified.
JN210: (2012-08-01 05:12:50)
ah I got ya, because I saw the tab missing and wondered where it went.
862sik: (2012-08-01 06:15:10)
So, stop playing with your lights and post some pictures of the output. I know how you can get carried away by just driving around with new lights LOL.
JN210: (2012-08-06 18:04:00)
Heres a close up, and I washed it last night and no water in it either, so its sealed pretty well.
[archived image: headlight11.jpg]
862sik: (2012-08-06 23:52:39)
Thats good that there is no condensation, that means the vents I did worked perfectly.
Can you take a picture a little further back? I want to see how much the headlight bezel covers the actual lens housing.
Rick88ss: (2012-08-07 01:09:38)
Looks really sharp.
Are you gonna be making any more complete units?
Does the complete headlight bucket need to come out to install these?
862sik: (2012-08-07 05:33:51)
Im not sure. Money talks. If I do, I may just make the lens. But possibly if someone else were to buy the projectors, as well as the housings and just ship them to me, it would be easier than me just having to cash out for them.
As for the bucket, yes. Removing the light without the bucket I failed at doing lol.
JN210: (2012-08-07 05:45:16)
It is EXTREMELY easy to install these, take the bucket out and take out the lights. dont even have to take off the cover.
862sik: (2012-08-07 06:39:15)
Didnt you have to take off the cover to align it?
JN210: (2012-08-07 08:19:04)
[quote]862sik wrote:
It is EXTREMELY easy to install these, take the bucket out and take out the lights. dont even have to take off the cover.
Didnt you have to take off the cover to align it?
nope, theres a screw underneath the lid that you can turn to align the lights.
862sik: (2012-08-07 10:30:08)
I meant horizontally
When I gave it to you I made. Sure it was pretty straight. So maybe you didn't have to fuss with it
Windzer: (2012-08-07 21:19:32)
I would buy the fuck out of those if they were offered… just saying
862sik: (2012-08-08 06:24:52)
Haha many.people have said that…then they never come through
RXGhost: (2012-08-08 13:39:45)
[quote]862sik wrote:
I would buy the *beep* out of those if they were offered… just saying
Haha many.people have said that…then they never come through
i have cash in hand i know you were not interested in making a lot more of these but if you make a group buy thread like shamwow did for the s-13 conversion kit, i would put a deposit down same day
DeleriousZ: (2012-08-08 14:09:09)
Yeah start up a group buy with potential pricing, you might be surprised at how much interest there is!
Windzer: (2012-08-08 16:48:00)
[quote]RXGhost wrote: [quote=862sik]
I would buy the *beep* out of those if they were offered… just saying
Haha many.people have said that…then they never come through
i have cash in hand i know you were not interested in making a lot more of these but if you make a group buy thread like shamwow did for the s-13 conversion kit, i would put a deposit down same day
I would be down for depositing on that after the 17th. Definitely start an interest thread, and I would be in with deposit then!
862sik: (2012-08-08 19:52:54)
Would there be people just interested in the lens, and then do it themselves?
DeleriousZ: (2012-08-08 21:02:50)
The lense definitely seems like the hardest part! I wonder if there'd be a deal to swing with the hid kit retailers if you ordered in sets of 10 or so though?
RXGhost: (2012-08-08 21:31:43)
I would be interested either way i don't mind doing a little bit myself
862sik: (2012-08-08 23:57:20)
Honestly, I get all my stuff from one company…www.theretrofitsource.com. So the only deal that I would possibly be able to get is in a bulk buy. But then the cost will still be with shipping the hid kit to you guys. If I were to get ebay junk I can get a much better price through a friend thats a distribitor of them, but I know they wont last and personally dont like any of their stuff and trust my company. I like quality products, that I know I have proven myself.
So its kinda a wash, and im not trying to make hella money by upselling product and then charging labor to do the work. But if I were to get everyone a HID kit with the lights, then any issues with the ballasts or the bulbs would be on ME. I have no control what happends on the other end. Then you guys would have to send the ballast to me, then I would have to send them to the company…Then wait for it to come back…then ship it back to you…to much to worry about. So thats why I prefer people to buy their own kits and probably even their own projectors then ship them to me. (If I do start doing this.)
As for the lens, it did take some time. But those I can do with no problems.
DeleriousZ: (2012-08-09 01:05:59)
Yeah, that website seems like THE place to go when looking for hid retrofits. High quality, great reviews and decent price. I've been looking into them for doing a retrofit on my scooby too.
Perhaps the lens and a solid parts list/ writeup on how to do it would be enough? I'd be totally happy with that
RXGhost: (2012-08-09 14:08:20)
I have no problem with that, the lens and solid write up would be perfect for me
862sik: (2012-08-10 15:57:04)
Interesting, thanks for the input!
862sik: (2012-11-24 08:46:37)
So im planning to pick up another bucket from the kouki at the junkyard for another retrofit.
I already have another one in process for someone here, and will probably make one for the zenki all in one shot before I go on vacation in the middle of december (which also means I should get them done before december 14). These funds will help my vacation fund lol.
Anyone want a set? I dont want any maybes....I ask for a 150$ deposit to start.
kouki-1 set avalible 320$
zenki-1 set avalible 275$
edicer2: (2012-11-24 10:06:43)
not bad pricing!
G-E: (2012-11-24 13:04:52)
Just curious, did you try putting back the oem glass on the kouki lights?
As an alternative:
I'm tempted to suggest mounting the projectors on the metal frame behind the popup frame, which you remove the majority of to allow the projector to sit stationary with the lid moving around it
So you just retain the lid and front cover for looks, the projector will sit higher, the lid will probably close to about where the light cutoff plate is
Downside is less width to your light dispersion, but that's nothing you couldn't fix with hid fog lamps when you need…
862sik: (2012-11-25 04:03:52)
I haven't tried using the factory glass. When I work on it ill do it to see how the output is.
As for putting the projector inside the housing of the car…I thought about that. But the projector would have to sit at a angle. If you notice the factory housings the bulb os offset
862sik: (2012-12-12 06:47:31)
Here is another set that I been laggin to complete.
I just aligned them, I think its pretty sweet. There is a little more foreground. When I align them they are like 33 off the ground so you obviously dont see the foreground.
862sik: (2012-12-12 06:51:49)
Well, I decided to try on one light with the projectors. These were taking at the same time and with the same bulb, only difference is of course the lens. Its not that bad, I think the proximity of the projector lens itself to the factory glass lens eliminates hot spots that is created by the glass. But I obviously couldnt tell how much light is lost, but I saw a small difference.
Condition of the factory glass.
Cutoff with one projector
Side view Cut off with one projector
Cut off with the projector and the factory glass lens.
Side view of the projector with the factory glass lens
Ven: (2012-12-12 07:17:30)
Me likes with the non-factory glass better. Not to mention probably looks aesthetically better with a clear lense on there than the factory glass.
862sik: (2012-12-13 05:57:20)
I got to agree with you. But it was interesting to see how it would look. Im surprised there isnt much more glare everywhere else with the factory lens.
DeleriousZ: (2012-12-13 05:58:56)
[quote]862sik wrote:
Me likes with the non-factory glass better. Not to mention probably looks aesthetically better with a clear lense on there than the factory glass.
I got to agree with you. But it was interesting to see how it would look. Im surprised there isnt much more glare everywhere else with the factory lens.
I agree, that's a pretty darn solid cutoff line for going through a fluted lens. I wonder what it'd look like if all the flutes were ground off and the glass was polished?
G-E: (2012-12-13 06:57:15)
I like the factory glass look for stealth and the light pattern is also very good…
862sik: (2012-12-13 06:57:45)
[quote]DeleriousZ wrote: [quote=862sik]
Me likes with the non-factory glass better. Not to mention probably looks aesthetically better with a clear lense on there than the factory glass.
I got to agree with you. But it was interesting to see how it would look. Im surprised there isnt much more glare everywhere else with the factory lens.
I agree, that's a pretty darn solid cutoff line for going through a fluted lens. I wonder what it'd look like if all the flutes were ground off and the glass was polished?
Probably it will look good. Basically the thick glass will kill some of the sharpness of the cutoff but it will still be there. My brothers 91 accord has thick glass headlights and I put these projectors behind them. Its not that bad. But whats the point of going through all the work of grinding down the glass and polishing when you can just do these lenses that I made lol.
DeleriousZ: (2012-12-13 15:57:21)
Mainly being able to replace a lense quickly and easily, rather than having to wait for a replacement to be produced. That and if you grind off everything except the DOT markings, you might pass inspection lol.
862sik: (2012-12-17 06:45:06)
haha clever. Im glad we dont have DOT inspections…but we do have smog..... :-(
862sik: (2013-01-17 04:20:55)
Ran into an issue that I didnt experience before. Was doing a final test at my work and our temps are around 40 degrees (yes not cold to you northern state guys) but I saw that the lens was fogging up on the bottom. The Last time I did j18's it was in the summer time, but I remember putting the lights in the fridge and then seeing if it will fog.
So I played with the vents and noticed that with a bigger vent on top the fogging went away. After a few stores I finally found a bigger vent, drilled the hole bigger to accomodate it. Unfortunatly today wasnt as cold but it was doing great. Tomorrow morning ill test the headights when its super cold and see if they fog up.
dayoldcustoms: (2013-02-14 08:14:58)
mini H1 lights look pimp on the CB7 maunly because the glass doesn't have all those ridges the Z does, it has all of like 3 lines i think, i used to do that and black-house/yellow high tint on them all the time lol
862sik: (2013-04-10 08:39:22)
Progress!
I hate condensation…I hate it. lol
Ven: (2013-04-12 22:49:30)
Good news. I feel someone else is getting a set too but there's no pictures.
862sik: (2013-04-13 01:28:42)
Yea I havent posted any pictures cause I been working on his set for to long. I finally fiqured the condensation issue that I didnt have with the first one I made. Now im cleaing it up and making a new lens because I hacked it to see if I can ventalate it better.
I spent many late nights back at work with these suckers on the bench. Each test was 30 minutes burn in time, 30 minutes defogging time (so 1 hour each modification)…literally it was like I was living at work…going home at 12 midnight sleeping at 2am, going back to work at 8 in the morning. I still got no where, almost gave up on the whole thing. I resealed it a few times, put tape on certain areas to make sure there wasnt a bad seal. It was difficult cause I can only work on it 2 nights a week when my boss was for sure not going to be at work. I could of done it at home but the voltage regulator for the HIds is much better at work than draining my battery in my car at home at night, every time.
I even purchased these expensive as hell vents 40 bucks for 3 little goretex patches to find that I didnt need them.
Basically what was going on was after about 20 minutes it would form condensation on the bottom of the lens. I drilled bigger vents, and even added vents with no sucess. I even enclosed the projector so the heat wont travel inside the light, fail. I found that if you put a bigger vent up top, 2 tiny vents near the lens, and one smaller vent in the rear bottom…the air would circulate to the front of the lens and not form condensation. Having to many vents interfered with the airflow inside the headlight.
So now im going to clean the snot out of it, grind the old stuff off (which is a bitch) and repaint it. After taking these lights apart at least 10 times im going to try a different sealant as well, something a little easier to work with and maybe a little more reliable in the heat. The old sealant was great even with heat. But someone pointed out in a hot climate it may still hold but you may be able to pry the lens off. I tested it and it would have to be pretty darn hot, over 100 degrees outside.
862sik: (2013-06-06 02:26:53)
Well im proud to say that all the issues with condensation are gone let them run for 20-30 minutes a piece and no issues with condensation. Finally fixed and figured out! I made a set for boosted300 and after hours and late nights of hating the lights, im proud of them. Completely changed the sealant also, now I use black silicone, that other stuff was a mess…especially after all the re-do's. Unfortunately I don't know when he will get them on, but they were aligned to the best of my ability and it arrived safely.
Ven: (2013-06-06 02:40:22)
Me next! lol
PulseCode: (2013-06-07 03:46:51)
GOOP adhesive works great for stuff like this and it's clear. I wouldn't expect you to change adhesives
since you have come this far. I just wanted to give you a heads up- maybe for your next project.
862sik: (2013-06-07 06:20:09)
HAHA BRO, Let me tell you…goop did not work! LOL. It softened it up but it was still stringy and messy. I almost threw them away LOL. Soaked it in a tub of gasoline and it came off like nothing. Its damn good sealant, and very strong. But it wasn't as clean as id like it to be, and if you mess up one little spot, you have to take it apart and do it all over again. Now with the silicone, I got clean lines and almost no clumpy areas. YES IM THAT ANAL lol.
862sik: (2013-06-07 06:21:07)
Serious inquiries only lol
Ven: (2013-06-07 07:34:22)
Oh, it's cereal!
1artworkz: (2013-06-08 16:49:38)
I have been following this build and applaud your creative genius. This information will be very helpful when I do you front end conversion. Thank you.
862sik: (2013-06-10 06:45:09)
No problem. Even though Id like to make money off of these, I still like to help the community. I have done research on custom lights that people charge to modify, and they are upwards from 200 to 600 dollars labor HOLT FCUK!! I don't have the skills or the tools like some people here to create really usefull mods, but if I can make a few bucks without ripping people off and make people happy then im definitely a happy camper. I just wish I had more time to do things like this. Probably since I worked out all of the bugs, I may do another set to really see how long in reality it will take me without all the setbacks. YOU my friend aren't that far from me (sacramento)..kinda nice to have some fellow z31 members near me.
862sik: (2013-06-11 06:35:43)
This is what I had to deal withcondensation wise. BTW im using the old sealant in this picture.
This is how I put together the lens.
And I sandwich them till they dry
Finished product
Here is what the new sealant looks like, IMO its much nicer.
862sik: (2013-06-11 06:37:48)
So old sealant vs new [archived image: headlight11.jpg]
G-E: (2013-06-12 04:26:05)
Nicely done
les_joey_paul: (2013-06-12 12:41:52)
Looks amazing dude! Glad to see its come together Like this. I'm impressed tbh
862sik: (2013-06-16 09:31:05)
Thanks guys. Lets hope my next set is quicker. I just made another lens, I have no clue what happened but it didn't seal 100% on the acrylic. It wont leak, but it just wont look good lol. I guess Ill sell that one off as scrap LOL.
fgb2010: (2013-06-17 00:24:23)
Planning on making a set to sell [archived image: biggrin.png]?
PulseCode: (2013-06-17 01:12:36)
Thanks for the heads-up. This would be the first time for me, where GOOP was not a good choice for the application. I take it the black silicone sticks well to the Plexiglass?
862sik: (2013-06-17 05:09:09)
The silicone worked out perfect. I tried silicone to hold a piece of lexan to the front of my bumper years ago and it still stuck till this day. The thing I like about the silicone is that regardless of the heat, it wont loose its integrity. The other stuff I was using was fine, but there will be the day its 120 degrees outside in direct sunlight and someone will pull really hard (I mean MEGA )to take off the housings. Don't want that lol. If you also think about it, aquarium glass are bonded with silicone, and they can hold back a lot of weight.
862sik: (2013-06-17 05:12:40)
Haha, A few. I already sold 2, someone on the forum just hit me up for another set. I already started making lenses. =)
88Turbozx: (2013-06-19 01:09:41)
Pricing? [archived image: tongue.png]
les_joey_paul: (2013-06-19 03:18:44)
Id like to get in line for a zenki set (:
gorekill: (2013-06-30 15:02:59)
I would like a set for my Kouki. [archived image: smile.png] Whenever you have one available.
How much are you asking for the complete kits?
862sik: (2013-07-04 06:53:43)
Did a little work on these today. Its been so hot lately that its hard to work. 103+ temps make me grumpy. But the housings now have a coat of primer on them for now.
Ven: (2013-07-04 17:36:15)
Beautiful work as usual. I love the halo. I see the ideas are branching out.
stufferton: (2013-07-04 19:45:32)
These are starting to look really top notch. I've been wanting to contact you about a set for a while now, but aren't ready to install them yet so I've been holding off. Making me want to splurge on them anyway *shakes fist*
Good work ser, keep it up.
862sik: (2013-07-04 20:46:45)
Thanks guys. You guys should of seen how big these were! The Halo thing is taking some tweaking, they don't fit correctly. So its going to be a little work.
jazztrumpet439: (2013-07-04 21:12:58)
How much are you asking for the Kouki set?
862sik: (2013-07-08 07:50:15)
That seems to be a question on everyone's mind. As of RIGHT NOW your looking around 320-360 plus shipping for the set. At that price, that includes the projectors with decorative shrouds, lens, the factory headlight buckets, everything for a plug and play setup minus the HID stuff. Price is not set in stone, price may vary.
It may seem like a lot, but honestly im not making much off of each set. I asked for a set of custom lenses to be made by someone else and their going rate was $80 for each for a very thin acrylic and ONLY if I had a mold for them. If I were to charge what I SHOULD charge with a custom lens and "professional labor" , add 250 to my price or so and that's a good real number. No lie, real talk.
862sik: (2013-07-23 07:31:00)
I hate waiting for parts. So in the meantime I decided to FINALLY do a set for my zenki. Don't know if Ill keep it. I don't even drive this car at night LOL.
les_joey_paul: (2013-07-23 10:44:23)
Nise!
Careless: (2013-07-23 11:22:00)
cool. any pics of the build for these new ones so i can copy ya (for myself only, of course) :-D
looks good.
glass lenses or plastic from ebay?
MagicZ31: (2013-07-23 16:16:19)
Is there any warranty for your items?
RocklinMike300zx: (2013-07-24 01:40:34)
Most likely not unless it's hardware. I don't want to speak for him but considering how much work it is to make each unit I can't see him really wanting to warranty the items with a replacement if they fail. Of course all things considered the only probably failure is the lights themselves which may have their own warranty from the manufacturer.
MagicZ31: (2013-07-24 02:01:16)
I mean if we buy his item and it comes broken or if something happens..
Ven: (2013-07-24 02:10:35)
Anyone is crazy if they don't think what 862sik offering is a killer deal. Go out on the interweb to websites like Clearcorners.com etc and see what they're charging for projector kits. Not to mention we've seen examples installed on cars and it looks GREAT.
Again
[archived image: headlight9.jpg]
[archived image: headlight3.jpg]
Look at that cutoff!!! And those are lights without any extra fancy housings, leds rings etc installed.
JN210: (2013-07-24 02:59:11)
Im still extremely happy with them, they work amazingly and look fantastic, had lots of comments on em.
RocklinMike300zx: (2013-07-24 03:46:02)
862sik, I owe you some money anyways, I feel like I should get in on a pair of these to be honest, haha.
862sik: (2013-07-24 06:31:49)
The warranty is kinda hard with custom pieces. Everyone will go through different climates and different situations which makes it hard to give a warranty. At the moment im putting the purchase of the projectors on the buyer, that way if you have any issues with the projectors itself it will be warrantied through you and the company, and not me. I can only do so much in making sure the unit works correctly and that its installed.
The lenses themselves that are made by me should not leak. I always soak them in water to see if water gets through. Fogging though will happen, and I have done a shit load of testing to eliminate that issue, but it will still happen. The alignment wont be spot on, but all you have to do is rotate the projector a millimeter or so. I try my best to align them to eachother on a bench.
IF the unit comes broken, I would want complete honesty and need pics. I try and package them very good. This is what insurance is for from UPS.
862sik: (2013-07-24 06:34:02)
Those ones are pilot housings from amazon/ebay. They are better than the glass ones I think personally, but they do cost a little more. I have done both and the glass ones on ebay with the city light built in is very convenient to run the high beam wires.
HAH build pics…HAH! Which housings, kouki or zenki?
862sik: (2013-07-24 06:36:02)
Its true, the price im selling these for is not much. It may seem like quite a bit, especially for the custom lens. But FOR NOW this is what the price is.
And bro, align your lights…you will be even more amazed…at least make them level and straight to eachother LOL.
862sik: (2013-07-24 06:37:22)
HAHA you disappeared for a long time!
Ven: (2013-07-24 12:51:20)
862, check your pm
MagicZ31: (2013-07-24 14:21:47)
Thanks for the info. These awesome projectors will be my last investment.
862sik: (2013-08-05 06:06:18)
HAh, you want this set? Ill give you a good price…
chris: (2013-09-17 01:42:28)
862sik: (2013-09-17 03:48:02)
Glad your happy, now fix those adjusters!!
LA KINGS: (2013-09-17 11:36:46)
200mm Hella H4 housings. Best headlights I've ever used
newsieone: (2013-09-17 13:22:27)
+1 with 100/50W H4
862sik: (2013-09-17 18:05:52)
Lol wrong thread??
862sik: (2013-11-07 07:00:00)
Hey guys, I have some time and have some parts I need (minus the projectors). Able to make 2 sets at the moment. If you want a kouki set let me know.
Turn around time should be 2 weeks once I receive the projectors. Price is around 350+shipping. Includes everything, even projectors.
Also if you just want the lens that can be arranged.
Ven: (2013-11-07 12:37:53)
These look great
and that cutoff!
862sik: (2013-11-07 18:01:54)
Those look good man! Glad they are holding up!
zengineer: (2014-06-19 18:04:17)
Interested in a set of Lenses. I have cash.
Sharpen047: (2014-06-20 01:06:37)
they sell all of that stuff at the retrofit source. thats where i got my lenses for my x5s.
862sik: (2014-06-20 03:11:13)
Not my lenses…lol
midian: (2014-11-11 05:22:26)
btw, using JDM/EUDM/AUS buckets and bodies -you can make kouki -style into zenki:-)
862sik: (2014-11-11 05:54:53)
I really would! Just cant get a hold of them for a good price. I was going to adapt and modify the zenki lights, but no one wants to be the person to front the cash lol
midian: (2014-11-11 13:16:43)
pm-d.
midian: (2014-11-12 12:19:06)
btw, some 2 variants of making glass from plexy
http://www.drive2.ru/l/1063693/
midian: (2014-11-12 12:23:32)
and this
http://www.drive2.ru/l/288230376152632714/
862sik: (2014-11-12 17:30:12)
I saw that and wanted to work with vacuum forming. But the thing I didnt like is once you get the shape you want and you cut it…your mounting surface is very thin and once you apply your sealant you will see it through the front of the lens. Thats why I used 1/4 thich for a very clean oem line.
Another reason I didnt want to vacuum form is that your limited by the thickness of the acrylic. You have to use thinner stuff and after asking a few guys who does vacuum forming is that they get pitted easier and you have to find the perfect temperature so they dont bubble. I didnt want to waste a whole piece of acrylic everytime I screwed up so I did it with my method.
Im not saying it cant be done....but the results looked better and more refined and oem like imo with the way I did it. Its like when you get things from ebay that are "euro clear" it just doesnt look right lol
midian: (2014-11-13 05:14:28)
understood. these are 4mm thick maximum (e. g. 3/16). and cocernin ebay-yeah, that's so.
btw-you can make it even from 1/2inch plexi, but you'll ought to cool it down in owen too.
862sik: (2014-11-13 08:57:37)
If you can do it, go for it lol. My girlfriend also gets mad when I use my oven like that. So im a LITTLE restricted lol!!
midian: (2014-11-13 11:56:54)
ha-ha-ha!
that's right-they understand almost nothing when you need to make smth. for your car :-P