1351 replies to this topic

[martinroger]

So back to the headlights... Waiting for Tom's reply, has anyone received theirs?

[fezzasus]

Yes. One pair with a matt black finish, bixenon units and a halogen main/sidelight configuration was delivered in September, before I broke my hand.

Next up is a matt black pair with bixenon/main LED and sidelight, and an equivalent CF pair. The CF pair were finished some time ago but the rear housing needs revising as does not have the right clearance

Clearance is the big issue with this project; from ordering the original CD headlights I found that it was relatively easy to integrate a better dipped beam, and main beam unit. Without a back this fit well into the space left by the original headlight. That's when I invited orders; with the work being one of scale (easy) and one of making a rear housing to protect all the sensitive parts and allow the unit to fit into the original space left by the original headlights.

That latter requirement has been a huge sticking point. These units use larger bixenon projectors, wider and longer than the original, have to accommodate a xenon ignitor, ballast, and somehow still mount to the original mounting point and clear all the other elements found in the headlight cavity.

I have made about 30 different rear housing iterations; it's not just working with the available void, it's also designing a part that can be removed and re-installed without fouling anything. This has lead to a few of the false starts; early last year I was convinced I could deploy them, and built up quite a few pairs before finding faults with the housing.

So is it better to have put something with faults out earlier, or wait until it's right? I have focused on the latter.

[Dunk]

Yes. One pair with a matt black finish, bixenon units and a halogen main/sidelight configuration was delivered in September, before I broke my hand.


Next up is a matt black pair with bixenon/main LED and sidelight, and an equivalent CF pair. The CF pair were finished some time ago but the rear housing needs revising as does not have the right clearance


Clearance is the big issue with this project; from ordering the original CD headlights I found that it was relatively easy to integrate a better dipped beam, and main beam unit. Without a back this fit well into the space left by the original headlight. That's when I invited orders; with the work being one of scale (easy) and one of making a rear housing to protect all the sensitive parts and allow the unit to fit into the original space left by the original headlights.


That latter requirement has been a huge sticking point. These units use larger bixenon projectors, wider and longer than the original, have to accommodate a xenon ignitor, ballast, and somehow still mount to the original mounting point and clear all the other elements found in the headlight cavity.


I have made about 30 different rear housing iterations; it's not just working with the available void, it's also designing a part that can be removed and re-installed without fouling anything. This has lead to a few of the false starts; early last year I was convinced I could deploy them, and built up quite a few pairs before finding faults with the housing.


So is it better to have put something with faults out earlier, or wait until it's right? I have focused on the latter.

Thanks Tom.

Like Rusty, I'm in the "been happy to wait" camp.

Edited by Dunk, 13 February 2020 - 11:42 AM.

[FLD]

Yes. One pair with a matt black finish, bixenon units and a halogen main/sidelight configuration was delivered in September, before I broke my hand.

Next up is a matt black pair with bixenon/main LED and sidelight, and an equivalent CF pair. The CF pair were finished some time ago but the rear housing needs revising as does not have the right clearance

Clearance is the big issue with this project; from ordering the original CD headlights I found that it was relatively easy to integrate a better dipped beam, and main beam unit. Without a back this fit well into the space left by the original headlight. That's when I invited orders; with the work being one of scale (easy) and one of making a rear housing to protect all the sensitive parts and allow the unit to fit into the original space left by the original headlights.

That latter requirement has been a huge sticking point. These units use larger bixenon projectors, wider and longer than the original, have to accommodate a xenon ignitor, ballast, and somehow still mount to the original mounting point and clear all the other elements found in the headlight cavity.

I have made about 30 different rear housing iterations; it's not just working with the available void, it's also designing a part that can be removed and re-installed without fouling anything. This has lead to a few of the false starts; early last year I was convinced I could deploy them, and built up quite a few pairs before finding faults with the housing.

So is it better to have put something with faults out earlier, or wait until it's right? I have focused on the latter.

 

 

Hey Fez,

just out of curiousity / interest could you post a few pics of the light units and covers?  I can imagine this is a complete nightmare as the lights are rather small.  It'd be interesting for us 'great unwashed' to see the challenge you're facing and how difficult the problem is.

 

Given the sand around here, I'm not invested nor a mod (for now ).  I'm just interested in the technical aspects of what must be an epic project.

[Richard Hoogeveen]

Thanks Tom.

Like Rusty + others , I'm also in the "been happy to wait" camp.

 

But If I hear Mat black, Led brrrr    

 

Cheers !

 

Richard

 

[harrytx65]

Hi Tom

I'm one of the happy waiters too.
Good Things come to those who wait...

Thank you very much for that great project!
And I know you are doing that in your free time.

Cheers

Harry

[WazzaVX220]

I'm in!!!!!!!

 

But what about our Failing (interior) headlight switches????

 

 

[Code Monkey]

I'm in!!!!!!!

 

But what about our Failing (interior) headlight switches????

 

Better off replacing the switch with a relay to turn lights on always with the ignition.

Means lights run in daytime, but not like the cars are big old lumps to stand out on the road amongst the SUV's. 

[zaimon83]

Finally sat down with all my supplier costings to put together total cost and final purchase price.

 

Headlight details:

 

- price is for a pair of front headlights, fully assembled

- available as both RHD and LHD. No price difference.

- Full one piece carbon fibre enclosure (available gloss or matt black)

- Headlamps as follows;

    + 3 inch Bi-xenon projector providing dipped beam and non-flash main beam (however can also be configured for H7 halogen if needed)

    + 90 mm halogen main beam unit with sidelight (same as OEM), providing main beam (including flash)

    + same as original indicator unit

 

Cost

 

£1300, £650 upfront cost, £650 payable prior to delivery

 

Production time

 

approximately 6 weeks, however this is small volume production at a carbon fibre site supplying motorsport, so rate depends on other work. At the moment the production time will be quick (summer shut down for F1 teams), however once into October it'll be very difficult to get any production time.

 

So.. who's in?

 

 

Hi Tom, I'm interested in a pair of headlights, LHD, with xenon.

 

Is it still possible to order them?

[martinroger]

Last I checked, Tom isn't taking new orders until he is finished with the first batch

[Foxy]

Last I checked, Tom isn't taking new orders until he is finished with the first batch

Is that info from this thread?

[martinroger]

Either that or by PM one or two years ago.

[Foxy]

Either that or by PM one or two years ago.

[FLD]

 

Yes. One pair with a matt black finish, bixenon units and a halogen main/sidelight configuration was delivered in September, before I broke my hand.

Next up is a matt black pair with bixenon/main LED and sidelight, and an equivalent CF pair. The CF pair were finished some time ago but the rear housing needs revising as does not have the right clearance

Clearance is the big issue with this project; from ordering the original CD headlights I found that it was relatively easy to integrate a better dipped beam, and main beam unit. Without a back this fit well into the space left by the original headlight. That's when I invited orders; with the work being one of scale (easy) and one of making a rear housing to protect all the sensitive parts and allow the unit to fit into the original space left by the original headlights.

That latter requirement has been a huge sticking point. These units use larger bixenon projectors, wider and longer than the original, have to accommodate a xenon ignitor, ballast, and somehow still mount to the original mounting point and clear all the other elements found in the headlight cavity.

I have made about 30 different rear housing iterations; it's not just working with the available void, it's also designing a part that can be removed and re-installed without fouling anything. This has lead to a few of the false starts; early last year I was convinced I could deploy them, and built up quite a few pairs before finding faults with the housing.

So is it better to have put something with faults out earlier, or wait until it's right? I have focused on the latter.

 

 

Hey Fez,

just out of curiousity / interest could you post a few pics of the light units and covers?  I can imagine this is a complete nightmare as the lights are rather small.  It'd be interesting for us 'great unwashed' to see the challenge you're facing and how difficult the problem is.

 

Given the sand around here, I'm not invested nor a mod (for now ).  I'm just interested in the technical aspects of what must be an epic project.

 

 

 

Anything?  Go on, just a sneaky peek! 

Edited by FLD, 15 March 2020 - 09:49 PM.

[Gonçalo Pereira]

Please...

[FLD]

[Rosssco]

Fezzasus - Headlight Self-Isolation Champion 2012-2020

 

[mbes2]

2021 is only 9 months away

[Gonçalo Pereira]

Hi Tom. how are you?

Did you finish any pair of units?

[Gonçalo Pereira]

????