Newest project: C6 headlights style on a C5 (56k take a nap)

For those of you who don't know, I now run a side-business developing unique automotive lighting products specializing in the C5 corvette. One of the most saught after products is a set of fixed headlights that preform like the C6. There are existing twin-projector lights available, but the optics are questionable and they have a distinctive "bulge" in the lens that looks like a frog eye. My objective was to build a sleek set of twin projector fixed headlights for the 97-04 corvette that could be easily installed, bolt on plug and play.

I started by basing the design off the Breathless Performance fixed headlight kit. Their headlights have the best asthetics, but the reflector low beam has a horrible pattern and output and the high beam appears to be a random foglight:

This is the breathless kit on a c5. It looks good, but performance is questionable.


I borrowed a friend's Breathless kit to get the specs for the lens. Other than the lens, I'm designing everything else from scratch.

I decided on Hella's new 60mm modular projectors for optics. They're inexpensive, HID friendly and small yet preform very well. They're also completely sealed for a nice look and moisture won't be a problem with them. They use 3-point adjuster mounts for easy aiming.

This is the low beam output with a 5000K 35w HID PNP kit:


and the high beam with a 65w 9005 halogen:


I began the design by building a mock-up of the mounting braket for the projectors. This braket is made of coroplast (a plastic version of cardboard used in bandit signs) The final version will be made from 1/8 Aluminum.


After i finalized the clearance issues, i designed a more stable design. This is the paper-model of it I took to the machine shop:


Here are some test shots of the Headlight running




Once I get the prototype frame from the machine shop I will begin designing a shroud mold for the lights. This mold will be used to make an ABS thermoformed shroud that will bolt onto the body panels under the hood and also serve as a mounting surface for the main lens. ALL hardware will be hidden under the hood.

I've been waiting a LONG time to do this project so i'm taking great joy in finally being able to see it come to life.

Wow, amazing man! As always, love your work.

Awesome! I don't have a vette, but I'm pretty excited to see a final product of this.

I wanted to do this same concept about 4 years ago and swing it into a small scale production, but college and not personally having a corvette prevented it from happening.

Also the fans in one of the breathless performance models look like crap.

Looks like it is coming along nicely.

Great job so far.

corvettecrazy wrote:

Also the fans in one of the breathless performance models look like crap.

yea...i think they're kina pointless especially since i think the reflectors in the breathless lights were sealed anyway

amazing sir

I had some extra time today so I went to the shop to work on the shroud design. I was originally going to do a simple circular cutout, but i decided to take the opprotunity to try something a little more unique.

The PVC is part of the substructure for the fiberglass that will be the mold.










The "tubing" does not affect the width of the output:







Prepped for fiberglass:

Looks good. If I may make a suggestion,it might look a tad better if you were to extend,then cut those pvc tubes at more of an angle to more closely match the lense.

Tat2Dragons wrote:

Looks good. If I may make a suggestion,it might look a tad better if you were to extend,then cut those pvc tubes at more of an angle to more closely match the lense.

I was thinking that, however if i extend the PVC any further, i risk affecting the beam width.

I dont think you will have a problem but, i hope the peices of pvc dont melt or warp from the heat of the hid's... awsome work so far

pgiordano wrote:

I dont think you will have a problem but, i hope the peices of pvc dont melt or warp from the heat of the hid's... awsome work so far

The PVC and fiberglass are going to be a mold. The actual shroud will be a thermoformed sheet of ABS. I'm not worried about heat with these projectors. Eveen after 5 minutes of operation they're warm to the touch but that's it....compared to the E55 projectors in my black car which get significantly hotter due to their all metal construction.

Radioflyer wrote:

Tat2Dragons wrote: Looks good. If I may make a suggestion,it might look a tad better if you were to extend,then cut those pvc tubes at more of an angle to more closely match the lense. I was thinking that, however if i extend the PVC any further, i risk affecting the beam width.

True,but I guess you wouldn't know for certain without actually trying.

Today I was able to do stage 1 of the fiberglass shroud mold. This comprised of a simple single layer 2-coat of fiberglass resin over a fleece cover.

Here’s the first coat


Once it hardened I cut out the holes for the projectors. This is pretty close to what the final design will look like.



The mold itself will not fit mounted long with the projectors since the inner structure doesn’t have enough clearance for the projectors, however the Thermoformed shroud will have PLENTY of clearance.



These pics show just how low profile the lights are. They hug the contours of the car very nicely.





For stage 2, I will use bondo as a filler material to smooth out the lines of the mold then lots of sanding. This shouldn’t take more than a few hours.

For the final stage, I will mount the existing mold on a slab of MDF with strategically drilled holes for thermoforming. I then plan to apply a layer of fiberglass mat over the entire piece and down to the MDF base. I will probably use about 3-4 coats of resin followed by a little light sanding to smooth out the top will make it ready to use as a mold.

If everything goes according to plan, I will have the molds finished and ready for use by Tuesday. (fingers crossed)

After much consideration, (and not being able to sleep), I decided the molds I made Sunday were not up to par both in quality and appearance. Since this mold will be used for repeated use, I felt it was best to remake it to be perfect even if it meant an extra day�s labor to do so.

I tore apart the molds I made yesterday and started over. The new design uses longer PVC shroud tubes cut at a sharper angle that more closely matches the contours of the car�s fender. I also got to use my new sander to make the �cut� perfectly flat instead of the guesswork I did with the earlier version. I measured them out so the longer tubes do not affect the beam width.

Checking lens clearance:

Checking beam width:

Shroud tubes mounted:


Fiberglassing (used a BUNCH more this time):


Test fit on projectors w/ frame and lens:




My poor dremel�lol:


Left and right:




Shroud and lens mounted test pics:






Note how low profile the lenses are:




Tomorrow starts stage II. Should be rather quick since the form came out so smooth.

Please tell me those body panels are loose in the last few pictures you posted.... their fitment is horrid.

Nice progress on the lights!

corvettecrazy wrote:

Please tell me those body panels are loose in the last few pictures you posted.... their fitment is horrid. Nice progress on the lights!

Sadly the panels are not loose. The fitment is the result of a poor repair job after a collision (previous owner) There are washers, random-head screws and such everywhere in the bumper and headlight area.

nice job keep up the great work you got going on there.

The new ones look 10xs better. Looks awesome dude.

Now that looks so much better. Great job!

Can you update us on how your light output is affected when driving at night? I figure when you're driving you would want a wide spread of light not a direct circular beam. Let me know if there are changes in the spread of light.

Projectors pattern test:

Low beam pattern: DOT cutoff with long step (5000K 35w HID kit)


High beam pattern: (Wide spread spot pattern) 55w halogen



I have the first thermoformed components. The trimming of these is a FAR cry from the ease of the original light cannons shroud. I'm glad to say that i'm getting plenty of use out of my new belt sander and band saw which DRASTICALLY speed up the proceess and cut down on the smell.

I only had a few hours at the shop this evening so i only got one side trimmed. Here are the pics:





With projectors: (they're just sitting there, not mounted)









The PETG lens material is very strong. While it's not as strong as lexan, it is extremely resistant to cracking. My thermoformer demonstrated by throwing a brick at a 1x1' sheet and i watched the brick bounce off without ANY cracking. The good news is that PETG is also less prone to scratching than polycarb. Any question i had about this as a lens material is completely gone. nevertheless, I will still be performing my favorite impact ballistics test on polycarb, PETG scrap and the original BPP lens material. This will be followed by a scratch resistance test.

The irony of it all.... my shop currently has 10 of the 12 flourecent lights out making evening work well...in need of enlightening (I know i'm horrible)

The next update will feature the first mounted and output pics with the new lenses.

wow that looks amazing

Those would sell great for RX7s!

test mouting pics

SLC on the drivers side, modified Specter werkes light on the passenger:





Note how close the lens matches body lines compared to the specter werkes lens. The Depo lens sticks out even further. Aerodynamically, the headlight bulge creates a low preessure area directly on top of the light causing lift on the nose at high speeds....something you REALLY don't want. The SLC lens maintains smooth airflow over the headlight area.



Just the SLC lens




Suggested painting line for "eyebrow"

that damn sexy! Great work as always!

someone needs their **** buffed out. lol


i love it. nice work.

Grinder wrote:

someone needs their **** buffed out. lol i love it. nice work.

Yeah it does but the clear coat on these cars is a PITA to buff out but micro mars really easily.

if for some crazy reason i decided to do what you are. retrofit some hids to my car.


what would it cost me? i have access to mills, welders, materials all for free.

yeah looks awesome (as always) where to you find your projectors at?

Grinder wrote:

if for some crazy reason i decided to do what you are. retrofit some hids to my car. what would it cost me? i have access to mills, welders, materials all for free.

Depends on the type of car, the projectors you chose to use, how handy you are, and many other factors.

rough estimate? so i can decide if it even worth it.

At least say what kind of car you have.

If you have a 86 **** with halogens then yeah it would be worth it. If you have a newer nissan with reflector HID's, no it is probably not worth the effort.

why you hit so hard.

1997 bonneville.

Grinder wrote:

why you hit so hard. 1997 bonneville.

Check out

http://s44.photobucket.com/albums/f16/corvettecrazyjnk/HL%20project/

The headlight should look familiar...

Because of the HL design making projectors fit is a LOT of work, but would be very worth it IMO.

If you are not on bonnevillepro.com you should join.

Finally all the components are in!! I decided to test the fitment on my daily driver to ensure the fitment will be good. The demo car had some body work done on it by the previous owner and I wanted to make sure there wasn�t any discrepancies in panel alignment.

This is roughly what it will look like as you assemble it:

Mounted projector/frame assembly. The joints are tab-welded for additional strength (this is the welding equivalent of a dovetail joint)




Shroud mounted:
Note: the shroud is a prototype shroud specifically formed and cut for fitment testing. The final shroud will be perfectly smooth like the lens.









Lens installed (not bolted on in these test shots)







Santa likes the clean lines:


Low beam testing on: 55w 6000K bulb




Beam pattern with lens. Note minimal distortion of cutoff with thee high quality main lens optics. Low beam width is about 110 degrees. Significantly wider than expected with the shroud installed.




Halo option:
Off:








On (shop lights on):




shop lights off






Halos with Low beams: shop lights off:







I was not able to get output pics outdoors today because of rain (I�m not getting my nice shiny camera wet)

I recently received the first projectors for the GP spot saver program along with a set of HIR bulbs that I will be testing tomorrow. I will be mounting a complete set of these lights for the first time on my car for a road test on Monday evening.

dude...slick **** rick dude. awesome!

looks really nice