Need info on DIY projection headlights

[GRNOVA]

This is what I am starting with:
They are real glass lenses w polycarbonate housings (I will have to get rid of the tri-bar)
Bulbs say: H4 12v 100/80W -non branded-
What I am striving to do is build a projector light by modifying this light if possible.
:idea:Pictures,links,past failures or someone who has succeeded in doing this all ideas will help good or bad.
https://static1.pt-content.com/images/pt/2010/04/IMGP0573-1.jpg
https://static1.pt-content.com/images/pt/2010/04/IMGP0574-1.jpg
https://static1.pt-content.com/images/pt/2010/04/IMGP0576-1.jpg
https://static1.pt-content.com/images/pt/2010/04/IMGP0577-1.jpg

[Chris 68]

will this be a regular projector? or are you using HID's?

[GRNOVA]

I would really like to focus on building Projectors, No HID'S I do not want to blind the on comming traffic causing them to crash into me!

[GRNOVA]

Can I just go to a salvage yard and get some off of a wrecked car?
Is there a certain type to look for? brand? size?

[dipren443]

Can I just go to a salvage yard and get some off of a wrecked car?
Is there a certain type to look for? brand? size?

That is the ideal path to take. Those glass lenses may or may not be useless. I cannot tell if they are fluted at all or if the back part of the housing dictates the beam pattern. If they are smooth glass, you are good. The fluting (if existing) and the shape of the reflector dictate the beam. With a projector, the projector housing itself dictates the beam. Hard to tell if that glass is fluted to be honest. It looks like it may be smooth.

I think alot of people doing this use Acura projector housings. Audi ones work well too. Source some projectors and size it up. Drill a hole in the back of the housing... I am looking for a DIY for ya...

Take a look through this thread.

http://forums.vwvortex.com/zerothread?id=3422984

[GRNOVA]

Well I stopped at the bone yard and found a 96 Mazda Melannia but everything looked vandalized..Boy have salvage yards changed.
So on the way home I thought who would have newer wrecked cars?
Auto body shops what a great idea here is what they gave me FREE
They are off a 2004 Mazda don't know what kind.
I wonder if these will work?
https://static1.pt-content.com/images/pt/2010/04/IMGP0578-1.jpg
https://static1.pt-content.com/images/pt/2010/04/IMGP0579-1.jpg

[GRNOVA]

That is the ideal path to take. Those glass lenses may or may not be useless. I cannot tell if they are fluted at all or if the back part of the housing dictates the beam pattern. If they are smooth glass, you are good. The fluting (if existing) and the shape of the reflector dictate the beam. With a projector, the projector housing itself dictates the beam. Hard to tell if that glass is fluted to be honest. It looks like it may be smooth.

I think alot of people doing this use Acura projector housings. Audi ones work well too. Source some projectors and size it up. Drill a hole in the back of the housing... I am looking for a DIY for ya...

Take a look through this thread.

http://forums.vwvortex.com/zerothread?id=3422984

It is fluted

[GRNOVA]

Ok, the tear down has begun. Got the lights out and the projector is exposed. Man those lenses are really gooped on, I used a heat gun to pry lens apart from case.
https://static1.pt-content.com/images/pt/2010/04/IMGP0580-1.jpg
https://static1.pt-content.com/images/pt/2010/04/IMGP0581-1.jpg
https://static1.pt-content.com/images/pt/2010/04/IMGP0582-1.jpg
https://static1.pt-content.com/images/pt/2010/04/IMGP0583-1.jpg

[dipren443]

It is fluted

YOU DO NOT WANT TO USE THAT LENS. I REPEAT THIS BECAUSE IT IS KEY. The light dispersion will look like crap and blind oncoming drivers and you will have less focused light with improper cutoffs. Find a 7" round with a clear lens, or make your own out of polycarbonate.

[GRNOVA]

I'm confused, I cant use the 7" round to put the projector light into because it is fluted?

[dipren443]

I'm confused, I cant use the 7" round to put the projector light into because it is fluted?

Correct. Look at the lens the projector fires through. It is there as protection only. The fluting on a glass lens is to properly disperse the light. The fluting dictates the beam pattern on a drop in halogen housing. On a projector, the projector itself dictates the beam pattern. So if you mount the projector with the fluted lens, you will have a proper beam pattern then being fired through a fluted lens.

[GRNOVA]

Ok Nick,

Let me get this straight. My plan was to cut a 2 3/4" hole where the halogen lightbulb was and push the projector light which would be in-closed in its own housing through the hole in the fluted lens. And your saying it will reflect the light from the projector incorrectly.

[dipren443]

Ok Nick,

Let me get this straight. My plan was to cut a 2 3/4" hole where the halogen lightbulb was and push the projector light which would be in-closed in its own housing through the hole in the fluted lens. And your saying it will reflect the light from the projector incorrectly.

Correct. Just look at what the projector fires through. NOTHING. Clear polycarbonate lens.

Look closely at the fluting of the halogen housing. The fluting is what helps dictate your beam. You are taking away the efficiency and the guided beam of the projector by firing it through a fluted glass lens.

[mc84_zz4]

Not to disagree, but I see the housing he is starting from has stamping on the reflector dish, but the lens is clear.
If he uses the entire projector and inserts it into the other housing, should give him projectors, adapted into the 6" housing.
Clearance on the back side of the housing could be an issue though, due to the depth of the projectors.

[mc84_zz4]

Here may be another source for projectors:
http://www.myhellalights.com/halogen_lamps/90mm_Headlamp_Module.html
http://www.myhellalights.com/halogen_lamps/50mm_Headlamp_Module.html
OR
Go all out and use the HID version of them:
http://www.myhellalights.com/hid_xenon_lamps/90mm_Bi_Xenon.html
I have NOT priced any of these, BTW

[GRNOVA]

Thanks for the links.

[dipren443]

Not to disagree, but I see the housing he is starting from has stamping on the reflector dish, but the lens is clear.
If he uses the entire projector and inserts it into the other housing, should give him projectors, adapted into the 6" housing.
Clearance on the back side of the housing could be an issue though, due to the depth of the projectors.

That is what it "looks" like to me... But I was taking his word that it is fluted.

[GRNOVA]

ok, the the lens right in front of the tri bar is flat smooth glass. The reflector behind the tri bar and lens is not smooth. But like MC 84 said when I put the projector through the hole I make in the " round housing" I should not make a difference if it is fluted or not ( the reflector not the lens)
Nick, I think we are saying the same thing.

[dipren443]

ok, the the lens right in front of the tri bar is flat smooth glass. The reflector behind the tri bar and lens is not smooth. But like MC 84 said when I put the projector through the hole I make in the " round housing" I should not make a difference if it is fluted or not ( the reflector not the lens)
Nick, I think we are saying the same thing.

Yup, we are good. My primary concern was that the glass itself was flat smooth glass. I was trying to differentiate between reflector and glass for that reason.

[GRNOVA]

http://www.hidextra.com/shopping_cart.php

Are these what I need when it says DS2 -12V 35W and these prices are really cheap.
Should I order these?

[dipren443]

http://www.hidextra.com/shopping_cart.php

Are these what I need when it says DS2 -12V 35W and these prices are really cheap.
Should I order these?

Hmm, those are cheap. At that price, if you cook a ballast, I guess you could just buy a new one without a large expenditure. Guessing those projectors use a D2S bulb?

For comparison, here are brand new Toyota/Lexus Denso ballasts.

http://cgi.ebay.com/ebaymotors/2-x-SLIM-LEXUS-DENSO-Xenon-BALLAST-HID-KIT-NEW-OEM_W0QQcmdZViewItemQQhashZitem518b1dc669QQitemZ35 0226335337QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAcce ssories

[GRNOVA]

I know they are cheap, but Being I am in the experimental stage I might just order them. I even called them they are in CA and asked them how long they would last she said 5 years on bulbs and ballasts.

[GRNOVA]

Well My kit has arrived I looked for a different one other than the one on ebay. I got it from a local car audio shop.
https://static1.pt-content.com/images/pt/2010/04/IMGP0600-1.jpg
https://static1.pt-content.com/images/pt/2010/04/IMGP0599-1.jpg

[GRNOVA]

Just test fired them up tonight! They work! now to retro fit them!
https://static1.pt-content.com/images/pt/2010/04/IMGP0603-1.jpg

D2s 6000K
https://static1.pt-content.com/images/pt/2010/04/IMGP0604-1.jpg

[GRNOVA]

I had a little time to work on the lights tonight.
Here are the projectors fitted into the housings.
And the link to the build pics.http://s300.photobucket.com/albums/nn13/tnt342/Pro%20light%20build/ Now have to fit them to The car.
https://static1.pt-content.com/images/pt/2010/04/IMGP0616-1.jpg

[78 Type-LT]

looks good sofar

[GRNOVA]

Just fit them to the car tonight
http://s300.photobucket.com/albums/nn13/tnt342/Pro%20light%20build/
https://static1.pt-content.com/images/pt/2010/04/IMGP0645-1.jpg

[GRNOVA]

Just added the final Pics http://s300.photobucket.com/albums/nn13/tnt342/Pro%20light%20build/
Here is the finished Product
https://static1.pt-content.com/images/pt/2010/04/IMGP0657-1.jpg
https://static1.pt-content.com/images/pt/2010/04/IMGP0659-1.jpg

[mc84_zz4]

They look great.
If they were mine, I'd remove the tri-bar. On an H4 the bulb tips are painted anyway, and the light is bounced off the reflector, but on the projector lens, it is blocking a vital area in the center of your light path. JMHO
Nice job!

[78 Type-LT]

looks great

[GRNOVA]

I thought that too about blocking the projector. Tried it both ways and it did not change a thing. So I kept them.

[mc84_zz4]

That's cool! I do like the look. :cheers:

[CamaroAJ]

what did you do to seal the projectors? the ones i have taken apart so far have had vents in them that could let water in.

[GRNOVA]

I rolled aluminum flashing around them and when I pushed them through the housing I sealed where it touched w/ silicone.

[slownova73]

subscribed for future reference! :1st: Nice job!

[vanwyk4257]

I'm not sure what car these are going on. I know that for the 4-headlamp vehicles with 5-3/4 headlamps BMW E34 headlamps can be adapted. That's what I have planned for my project.

[Rhino]

I thought that too about blocking the projector. Tried it both ways and it did not change a thing. So I kept them.

It will block a small amount of light, but it probably wouldn't be enough to distinguish a difference. Considering the additional light output you have I don't think I'd worry about it. With the bar installed, do you notice any additional light leaking outside of the intended pattern? My thought is that the light is reflected from the bar, onto the rear reflector, and back out the headlight.

Just for a little clarification for those of us just finding the thread, were these the original Mazda projectors you are using with the ballasts from the kit you just purchased?

[GRNOVA]

Yes these are the original projectors. With aftermarket ballast kit.
No I have not noticed any difference and I have removed the tribars to see if there is one.

[JRouche]

Hey Tim. Great job. I am gonna do something similar. I have some acura tl projectors I am gonna use, along with the tl ballasts.

After looking at all your pics I have a question. I am gonna use a tri-bar lamp also. It kinda looks like you modified two different lamps? The final one is an Adjure (pricey) lamp. But the pics during modification show a lamp that had a turn signal hole? The Adjures dont come with a turn sig hole that I am aware of.

And the glass lens looks like its diff in the modification pics.

Sooooo. Did you have the adjure lamps already then buy an inexpensive set of lamps off ebay to modify. Then use the adjure fronts on the ebay reflector???

I would like to get the adjures (I can get them for 160 bucks a set). But Im wondering for one if they are worth the extra cash over the ebay 40 dollar a set lamps. And if they would be as easy to modify. Like is the reflector plastic also. Or is it metal which might be harder to modify.

Anyway, any help??? Thanks, JR

[GRNOVA]

JR,
Yes I had the Adjure headlights and bought a 30.00 pair off ebay. One thing I ran into with the tri bar is that the glass dot hit the lens and cracked the one on the drivers side. The projectors with the tri bar was to long to fit into the housing. Also the ebay lights will not fit properly like adjure. I may have an extra ebay housing at home if you want it pm me.

[JRouche]

PM sent for some questions. Thanks Tim, JR