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.
Pictures,links,past failures or someone who has succeeded in doing this all ideas will help good or bad.

[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?

[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.

[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...mp_Module.html
http://www.myhellalights.com/halogen...mp_Module.html
OR
Go all out and use the HID version of them:
http://www.myhellalights.com/hid_xen..._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?