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Custom Pop-Up Corvette Headlights (for a friend of mine)

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Radioflyer

Joined: Sep 25 2007
Posts: 1563


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Post Sun Jan 04, 2009 9:18 am

A friend of mine (Larry) Has been helping me out with professional painting and body work for some time. Among the projects he helped me with were my custom pop up headlights. Iíve since sold them and Larry Really wanted a set. I set about re-working my original design to make it more user friendly. The new design features a few noticeable improvements over the original:

- Reinforced Aluminum Frame instead of simple Galvanized steel
- No heavy fiberglass trim.
- Easy to adjust high/low beam modules.
- Significantly less weight than the original
- Significantly easier installation.

The Equipment: I used Hellaís 90mm projector and Free form reflector Headlamp modules. They are completely weather proof and passed my high pressure water intrusion test with flying colors. This setup is using a 35w 6000k H9 rebased HID Kit for easy installation and good color contrast.

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The hinge bolts are stubborn
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Hinge Bolts removed, Allows access to the lifting arm mounting bolt:
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The Old Headlight getting removed
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New Headlight setup: (installs on OEM mounts)
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Relay Harness: Mounted using all OEM bolts (no holes drilled)
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Finished:
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My camera sucks at taking pics of lights.
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It should be noted that the Halos were tapped into the low beam wiring. This apparently provided enough of a load for the headlights to operate normally (instead of having to switch to high beams to lower the lights)

Output: This was taking at 15 feet (this was all the distance we had to aim) Note the Dipped beam Cutoff. A more even-spread pattern could have been achieved by spacing the bulb, but this pattern is perfect for high speed highway driving because of the extra intensity at the center of each cutoff. While itís not nearly as sharp as Mercedes or BMW projectors, it also didnít cost nearly as much.

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First test video: (same crappy camera) User posted image

I will have more pics/vids of the beam pattern early next week. Larry will be coming over to my house for final aiming of the low beams and high beams. In addition I will be installing a high-4 circuit that will allow the low beams to remain on when the high beams are activated.
mx107marlin

Joined: Aug 12 2007
Posts: 3095
Location: Fairborn, OH


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Post Sun Jan 04, 2009 10:26 am

Looks amazing, as always...

I'm sure the video doesn't do it justice, but those don't look very bright rolling down the road...
Radioflyer

Joined: Sep 25 2007
Posts: 1563


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Post Sun Jan 04, 2009 10:32 am

mx107marlin wrote:
Looks amazing, as always...

I'm sure the video doesn't do it justice, but those don't look very bright rolling down the road...


yea, the vid sucks. My camera's like 10 years old. I"ll be using a new camcorder on the next run and a newer still camera for night shots.
Kevin_S

Joined: Jul 20 2003
Posts: 2809
Location: WV


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Post Sun Jan 04, 2009 12:00 pm

Not a fan of the finished look (http://i27.photobucket.com/albums/c200/radioflyer1986/Radioflyer%20Customs/CIMG2304.jpg) :/
RRSport

Joined: Apr 14 2008
Posts: 306


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Post Sun Jan 04, 2009 12:19 pm

Are you going to make a face plate so they dont look so rough and moddified?
Radioflyer

Joined: Sep 25 2007
Posts: 1563


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Post Sun Jan 04, 2009 12:53 pm

RRSport wrote:
Are you going to make a face plate so they dont look so rough and moddified?


Yes. The Angel eyes made it impossible to get a mold that would fit. Larry prefers this look for 2 reasons:
a) the lights will only be up when it's dark and when they're up the CCFL angel eyes and HID kit will make seeing Any shroud nearly impossible
b) It makes the car look like the terminator.

I will be marketing a more "finished" version without angel eyes that will have an Vac-Formed ABS insert similar to this one (i tried to make this mold for the angel eyes)





This fiberglass mold was very rough an i didn't bother sanding it. I just wanted to see if i could get a good amount of clearance....and i couldn't. (several hours of sanding saved)
Ryan88

Joined: Aug 09 2004
Posts: 3516
Location: Pittsburgh, PA


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Post Sun Jan 04, 2009 2:26 pm

Looks good. How much do those projectors cost?
Radioflyer

Joined: Sep 25 2007
Posts: 1563


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Post Sun Jan 04, 2009 3:17 pm

Ryan88 wrote:
Looks good. How much do those projectors cost?


they run ~$60. that's the best price i could find.
MrJayDeeOne

Joined: Mar 26 2005
Posts: 1277
Location: Woodbridge NJ/Staten Island NY


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Post Sun Jan 04, 2009 4:57 pm

wow. amazing work.
Tat2Dragons

Joined: Jan 21 2007
Posts: 3404
Location: Baltimore Maryland


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Post Sun Jan 04, 2009 10:06 pm

Very nicely done. icon_smile.gif Bad ass garage too,or is that at a car dealership? icon_cool.gif
Radioflyer

Joined: Sep 25 2007
Posts: 1563


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Post Sun Jan 04, 2009 10:41 pm

Tat2Dragons wrote:
Very nicely done. icon_smile.gif Bad ass garage too,or is that at a car dealership? icon_cool.gif


Sadly, that's not my garage. It's the office area of my friend's body shop. he gets to park his car in the "showroom"
Tat2Dragons

Joined: Jan 21 2007
Posts: 3404
Location: Baltimore Maryland


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Post Sun Jan 04, 2009 10:43 pm

Radioflyer wrote:
Tat2Dragons wrote:
Very nicely done. icon_smile.gif Bad ass garage too,or is that at a car dealership? icon_cool.gif


Sadly, that's not my garage. It's the office area of my friend's body shop. he gets to park his car in the "showroom"


Lucky man. icon_smile.gif
Radioflyer

Joined: Sep 25 2007
Posts: 1563


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Post Mon Jan 05, 2009 9:04 am

Larry went on a drive with our group yesterday and got this wicked Pic:

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Tat2Dragons

Joined: Jan 21 2007
Posts: 3404
Location: Baltimore Maryland


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Post Mon Jan 05, 2009 9:33 am

Cool pic. icon_cool.gif is that a Z06?
Mrkai

Joined: Aug 07 2008
Posts: 361
Location: Virginia


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Post Mon Jan 05, 2009 10:20 am

love it!
justinwebb

Joined: Sep 15 2004
Posts: 3170
Location: Columbus, OH


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Post Mon Jan 05, 2009 10:33 am

Tat2Dragons wrote:
Cool pic. icon_cool.gif is that a Z06?

indeed it looks like one...and i see a badge on the side
knatebetz

Joined: Apr 19 2008
Posts: 1504
Location: Nebraska


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Post Mon Jan 05, 2009 3:17 pm

that's hot.. might have you fab me up something like this for my car. flip up headlights FTW
Radioflyer

Joined: Sep 25 2007
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Post Thu Jan 15, 2009 3:37 pm

I finished the molds for the ABS shrouds today and vac-formed the ABS into the first shrouds. The preliminary results were impressive as far as fitment goes. I'm planning on using ABS/MEK mixture to mold around the edges for a seamless finish between the bucket and shroud. I also noticed the OEM plastic texture isn't nearly as pronounced as the ABS i have. I'm going to sand mine down a bit for the final version before vac-forming it.

Headlights with molds (btw, these were a PITA to make)
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First Shroud (the small wrinkle is from me vac-forming the same piece of ABS twice.
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First and second shrouds:
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The OEM shrouds obviously still have leftover tape, hardened fiberglass and scuffs....all easily repairable.
02cougarman

Joined: Jun 23 2008
Posts: 924
Location: OH


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Post Thu Jan 15, 2009 6:10 pm

looks sick man.

How do you know where your cutoff should be?
Radioflyer

Joined: Sep 25 2007
Posts: 1563


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Post Thu Jan 15, 2009 9:55 pm

02cougarman wrote:
looks sick man.

How do you know where your cutoff should be?


The headlights sit 24" from ground level so at 25' (the traditional aiming distance) the lower part of the dipped beam should be between 20 and 22" off the ground.
02cougarman

Joined: Jun 23 2008
Posts: 924
Location: OH


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Post Fri Jan 16, 2009 7:38 am

shoot. im definatly not going to have 25 feet to adjust my cutoff when i get my HIDs
corvettecrazy

Joined: Dec 17 2003
Posts: 4357
Location: moved (twice)


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Post Fri Jan 16, 2009 8:06 am

02cougarman wrote:
shoot. im definatly not going to have 25 feet to adjust my cutoff when i get my HIDs


You can't tell me there isn't a single flat parking lot with a wall or building on one side in the whole city you live in.
02cougarman

Joined: Jun 23 2008
Posts: 924
Location: OH


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Post Fri Jan 16, 2009 8:16 am

never thought of that... i was thinking at my house.
Radioflyer

Joined: Sep 25 2007
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Post Fri Jan 16, 2009 10:43 am

corvettecrazy wrote:
02cougarman wrote:
shoot. im definatly not going to have 25 feet to adjust my cutoff when i get my HIDs


You can't tell me there isn't a single flat parking lot with a wall or building on one side in the whole city you live in.


biglaugh.gif biglaugh.gif biglaugh.gif
He lives in whoville
skillfullyboard

Joined: Jan 12 2009
Posts: 174


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Post Fri Jan 16, 2009 10:59 am

That looks really good man
Radioflyer

Joined: Sep 25 2007
Posts: 1563


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Post Sun Jan 18, 2009 8:38 pm

Final version with Perfected shrouds:

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Video comparison:

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Tat2Dragons

Joined: Jan 21 2007
Posts: 3404
Location: Baltimore Maryland


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Post Sun Jan 18, 2009 11:52 pm

Very nice,that video clearly shows an vast improvement over stock setup. icon_cool.gif
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