New Super headlights in progress :)

My current Specter werks setup is by far one of the best for sheer output and IMO looks freaking cool....however I'm not completely satisfied with the pattern. The cutoff is well crap compared to other xenon projectors.

The new plan involves swapping out a lot of things:

a) Replace low beam projectors with E55 Bi-xenon projectors from Mercedes

b) Replace high beam projector with halogen E55 single

c) Replace Hella Micro DE lights with OEM corvette fogs. Re-mount them 3" further back from their existing location to make clearance for custom grilles

d) Replace all Xenon bulbs to fit the new units: 880 and D2S bulbs.

e) Retrofit the Halogen projectors for H7 rebased Xenon kit

f) Replace projector lenses with ZKW crystal clear lenses

The predicted end result: Enough forward light to light a barbacue

Parts pictured:
(2) Mercedes E55 Bi-xenon Projectors
(2) Mercedes E55- Single Halogen projectors
(4) ZKW crystal clear lenses
(4) 90mm White CCFL Halos and transformers
(2) 55w 6000K D2S Bulbs with adapters
(2) 35w Kit with 3000K H7 Bulbs



The modification is scheduled for the thanksgiving break (when all the stores are closed and I have the whole day to do nothing productive

this one's going to be good (insert diabolical laughter)

I can't wait to see this!. You could probably chase some storms in the vette.

A-Ray wrote:

I can't wait to see this!. You could probably chase some storms in the vette.

actually, I'm starting to think they chase me....lol

Wow, cant wait to see how it turns out.

wow....The number of blind people is about to sky rocket...... where are my sunglasses?

God damn son.


And the best part about this build is that he is doing it all correctly. With the proper parts, and proper work. He is going to have some CRAZY light out put. But it all is going to be thrown down the road correctly. And won't blind anyone.

A+ my friend

Very anxious to see this build unfold.

i cant wait to see lots of pics

AutoAustin wrote:

wow....The number of blind people is about to sky rocket...... where are my sunglasses?

Blindness it not likly to occur. here's a couple preview shots of the E55 Bi xenons with 35w D2S bulbs and the standard lenses:



just one projector:


And the super cool high beam pattern:

i dont know, bright headlights are bright headlights. i feel bad for anyone you are behind. at least you care enoguh to put em in projectors and such that are meant for HIDs ant not just tossing em in reflector type headlights...

bro what are you going to do with the projectors you have now?..interested on getting them

cardude007617 wrote:

i dont know, bright headlights are bright headlights. i feel bad for anyone you are behind. at least you care enoguh to put em in projectors and such that are meant for HIDs ant not just tossing em in reflector type headlights...

You apparently don't understand how properly aimed and installed projector headlights work. As you are way off.

His headlights will bother less people than most regular reflector housing headlights.

blktbon20s wrote:

bro what are you going to do with the projectors you have now?..interested on getting them

I don't have any plans for them at the moment. Both sets take 9006 bulbs and i remove the cutoff shield from the high beams. if i were to sell them, i would include the 6000k 55w HID bulbs for the lows and the 3000K 65w Halogen for the high beams.

Make me an offer?

NICE man... looks like a sick project

AutoAustin wrote:

wow....The number of blind people is about to sky rocket...... where are my sunglasses?

cardude007617 wrote:

i dont know, bright headlights are bright headlights. i feel bad for anyone you are behind. at least you care enoguh to put em in projectors and such that are meant for HIDs ant not just tossing em in reflector type headlights...

This is known as retrofit (and is legal). There is a big difference between retrofitting and having plug and play kits. Retrofitted (projectors specifically for HIDs) have a distinct cutoff line. Plug and plays (not approved by DOT) dont have cutoffs and have lights that scatter.

You can see the cutoff here



However, they are aimed a bit too high especially for a car.

dcemureviews :
the first pic is an "out-of-car" test pic of the projector and the second pic is of the high beams.

Cutoff looks nice. Props for doing it right.

Radioflyer wrote:

dcemureviews : the first pic is an "out-of-car" test pic of the projector and the second pic is of the high beams.

OK to first pic.

But as for second pic, the low beam is also on, yes? the dimmer of the two lights is low beam since it has a cut off. The high beam is the bright light in the center? I ask because the aim of the cutoff is a little more than half the height of the garage door itself if it is indeed the low beam. A car's trunk isnt that high so the light would be shining into the persons back window which would result in glare and blinding the driver in front.

Like others said, props on doing it correctly, doing a retrofit and not going the plug and play route. If I had the money and time, I would change all my cars headlights with retrofits. Its night and day when compared with stock halogen and plug and play.

As always, I cannot wait to see your finished product.. some of the cleanest work I've seen is on your 'Vette

wow. Can't wait to see what you end up with.

Some progress made: (I'll REALLY dive into it after finals next week)

The SW projectors:
they're okay with the right tweaking, but I seek perfection!


Comparison SW vs. E55 projectors:


Custom Angel eyes:
Off

On


Projectors mounted.



The SW elevation aiming system is good for the SW projectors, but I'm working on a setup that would allow easy aiming of the individual projectors for a good beam pattern. on the low beam and LVL systems

I'm currently experiencing problems with the main lens clearance and trim piece mostly regarding the Angel eyes. I will be ordering new slightly larger angel eyes that will be re-mounted 1/2" further back on the headlight frame. Matt at Specter werks is helping find a solution to the plastic trim that normally hides the gap in the projectors. Hopefully the finished version will be ready for preliminary testing by Christmas.

nice.

You custom build those halos?

no he bought them from here and smoked them

pgiordano wrote:

no he bought them from here and smoked them

correct. I'll have to do it all again with the new larger ones.

Still....cant wait to see it done.

very impressed

lookin good

yey for retrofit... hid kits are lame.

im putting 4 tsx in my bike,.... making my own cut off shields to make them bixenon

SyTrepT wrote:

im putting 4 tsx in my bike,.... making my own cut off shields to make them bixenon

you have my attention....

+1 to tinting the halos. That looks bad ass! And you're high beams are sweet!

I love the smoked angel eyes. Very nice touch.

Headlight update:

Today's objective was to figure and mark the transverse mounting points for the projectors. I also decided that i wanted an even sharper cutoff and after tweaking with bulb spacing, I finally got what i consider to be acceptable. Since the curvature of the main lens will cause the cutoff to be a little blurry, i figured i'd start with something as sharp as possible:

In all the pictures, the projectors were ~20-25' from the wall.

Main beam projector: very clean cutoff.


Camera close up


LVL projectors (selective Yellow) These are halogen projectors and as such the optics aren't as fine tuned, but i managed to get them to behave


Camera close up:



Tomorrow....the fiberglassing begins

cant wait

Update: The Original Shroud I glassed simply wasn't up to par. I tried to make a second with a new set of measurements but it tore in the middle of glassing. I ran out of sweater fleece and had to make a christmas-eve Fleecing run. After nearly 3 hours of prep work (including sewing some parts of the fabric to the PVC. After 4 layers of glassing, and LOTS of trimming, i'm pleased with the result thus far. The Gaps between the shroud and projector are intentional. (this is where the Angel eye rings will go)



Rough sanded


I will be running then without the Shroud until the Angel eye rings come in. (i believe they got lost in the mail)

I will be using the fiberglass shrouds themselves instead of making an ABS mold from them.

A few shots without the shroud with main lens on:








Question: I have a few options for finishing the shrouds and i'm looking for opinions.
a) SEM Texture coat?
b) Flat, Semi gloss or Full gloss black paint?

gloss would match the cars color nicely. Like newer Corvettes.

defenitly gloss

match the finish of the vettes paint, whether it be full gloss or semi gloss from wear

Installation update:

I got the projectors installed and aligned. I still have a bit of tinkering to do with bulb positioning. The E55 projetors appear to have a warm spot that's usually at the center of the cutoff but with angled bulb spacing it moved a little. Since this was the first aiming, I opted not to attach the main lens cover (though the pattern is nearly the same with the main lens cover installed) All pictures were taken at ~20'

Disclaimer: Pics taken with a Casio Exilim POS on a tripod....they aren't the best pics.

The Low beam cutoff: Sharp and clean. I'm still trying to get some more color out of it though


The Sexy High beam pattern


The LVL (Low Visibility Lighting) Projectors. These are E55 H7 halogen projectors with an H7 re-based 3000K HID kit. These are for poor weather conditions and are aimed roughly 8 inches lower at 20 feet primarily for good foreground lighting with enough distance for safe-speed highway driving.


This is rear part of the LVL system. The row of 8 100mA high-flux red LEDs on my license plate have a viewing angle of 140 degrees and an intensity of 40,000 MCD. It helps make my car significantly easier to see from the rear in heavy rain/fog.




I'm still waiting on my CCFL halos and the shrouds should be finished by tomorrow.

Gorgeous!