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Projector lenses into GL/Loyale buckets


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70 replies to this topic

#1 Turbone

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Posted 03 August 2011 - 11:49 AM

We all know that the GL/Loyale lights are not the brightest setup around.
When I did my EJ swap I got about a 20% increase improvement from the updated charging system, but I wanted more. For about 5-6mo I contemplated and researched, looking at all the styles in current OEM systems. I was hoping I could make a factory system work, but nothing matched the GL bucket (go figure).
Then as my luck would have it, Mr Brat had a set of projectors he got off Ebay and decided to go a different route. I purchased the set from him and the real work began.

Posted Image
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No, these are not 7 colors and are 6K bulbs.

I first had to find out how the projectors would fit in the buckets, so I had to separate the lens from the bucket. I did this the same way the new gen guys do their plastic headlights, put it in the oven......300deg for 25min.
It worked ok. The sealant, being over 20yrs old, is a pita to pull apart.
I cracked on lens trying to separate it, mostly because I didnt heat it long/hot enough. Then you need to clean off all the old stuff, another pita.
The projectors fit perfect. My main concern was that they might be to long and I would have zero clearance with the glass.

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In order for projectors to work, you need a clear surface. The ridges on the inside of the OEM lenses are designed for 9004 halogen bulbs and to refract the light coming out, so it had to be ground smooth. I was planing on making a completely different lens at first, removing the glass and replacing it with plexi. I experimented with heating and forming, but it was hit and miss without the proper equipment.
My other option was to grind and polish the glass lens. I did a bunch of internet research on it and decided to give it a try. I had some glass polishing pads and polish I got from Griot's Garage and 3-4 different grits of 3M sanding disc. I used my cordless drill for starters. I made a circle that was somewhat bigger than the projector and got to work.
It was very slow going as I didnt want to overheat the glass and crack it.
I did start with a old headlight, I didnt want to ruin what I had on my car as they are the best I've found to date. I used a squirt bottle of water to keep things cool and went from the glass polish to eventually using rubbing compound. This got the heavy scratches and glaze off, then I had to use finer compounds like Mequires.
When I thought I had it clear enough I assembled it all and put it on the car for a test run. As you can see, theres quite a difference.

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So now that I knew it would work, I had to make things faster/easier.
As it was, I was spending hours grinding and polishing. I'm serious......polishing these lenses - without screwing them up - takes a long time, I have at least 8-10hrs of work in each lens.
If it wasnt for the drill press it would have taken forever and I probably would have given up.
I had a old Craftsman drill press (that I've used once and its been on my patio for over 10yrs), so I drug that out and set it up. This cut at least a day or two off the job.
The process at work.

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Besides the time involved with the glass, it was a pretty simple job.
Wiring is standard HID stuff, but I decided not to have the halo (blue) on with the running lights. I will wire it separate and use a switch - for show purposes (maybe).

Now that the projectors are done, heres were I make things over the top :D
These arent the projectors, obviously.

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Hmmm, what do we have here?

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LED strands. Very simple and easy to install......anywhere.

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If you look at one of the pics above, you will see that I removed the turn signals in the bumper and replaced them with driving lights (can never have enough light for my old eyeballs). So I had to relocate the turn signals up the corner lights.
I had extra LED's (when buying, you need more than what it takes. A strand can be cut every 3rd LED). So it wasnt really that hard to make them work as signals.

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#2 T'subaru

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Posted 03 August 2011 - 12:18 PM

Awesome job! Ive noticed the led patterns on some of the newer cars and your right, its over the top :slobber:

#3 elementskaytr16

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Posted 03 August 2011 - 12:30 PM

that is pretty sweet i want to do this now

#4 Numbchux

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Posted 03 August 2011 - 03:02 PM

pretty cool, not sure I would have done the LED strips....but it's certainly well done.


I looked a little into doing something like that on my loyale, but had zero confidence that I could get the lens truly clear. Good work!

#5 92_rugby_subie

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Posted 03 August 2011 - 03:04 PM

Thanks a ton for the write-up Rob!

Definitely looks like some work... But looks like the overall end effect is a great deal!

Would you say its worth it? Is the ability to see greater with these?

#6 suberdave

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Posted 04 August 2011 - 08:17 AM

I have thought about this many times... i even have a set of projectors in the garage.

glad to see that it works.

#7 Mr. Brat

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Posted 04 August 2011 - 12:04 PM

I am glad that all worked out for you. Looks great! :grin:

#8 eulogious

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Posted 05 August 2011 - 08:05 AM

These look sweet :grin: Glad it worked out!

Also thanks Rob for showing how to CORRECTLY add HID/Projectors in a car that was not designed for them. This is rarely done, so good job on doing it right and proving that it can be done! Good stuff man!

#9 bigjimd

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Posted 07 August 2011 - 06:56 AM

Pretty work!! What product did you use to seal the lens back up?

#10 Turbone

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Posted 07 August 2011 - 10:28 AM

The kit comes with sealant.
2 tubes of it to be exact and I only used half of one.

#11 bheinen74

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Posted 07 August 2011 - 10:46 AM

Did you drive with them at night enough to report back how they are doing? Would like some feedback of the useage.

#12 GeneralDisorder

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Posted 07 August 2011 - 11:21 AM

You did an excelent job with these! I've seen them in person and I must say they look very good.

Now you need to streamline the process so you can make them and sell them. :)

GD

#13 Turbone

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Posted 07 August 2011 - 06:55 PM

Did you drive with them at night enough to report back how they are doing? Would like some feedback of the useage.


Sure, I got a crappy cell phone pic so far.
So far, its 100% better than any EA82 OEM lighting.
Actually better than most new gen stuff too.

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The RX isnt my daily and I dont get out with it much at night right now.
Just going to have to wait till I get some pics. I would do it at home, but by the time its dark here its past 10pm. And I've already had my ******y neighbor yell at me for running my car while adjusting them, and that was only 9:30pm (yes, I know the law, its 10pm).

You did an excelent job with these! I've seen them in person and I must say they look very good.

Now you need to streamline the process so you can make them and sell them. :)

GD


If I do they will cost $$$$.
Buyer will have to provide lights and projectors too.
I already had visions (not good ones either) of glass lenses stacked on shelves. Either ready for work or broken :rolleyes:

#14 92_rugby_subie

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Posted 08 August 2011 - 01:58 AM

Whats this no running a vehicle past 10pm law!?

#15 Turbone

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Posted 08 August 2011 - 09:38 AM

Whats this no running a vehicle past 10pm law!?


No construction or loud noises after 10pm. Most counties have noise ordinances.
It really doesnt effect vehicles, but mine is louder than most newer cars.
80dB at 50ft is the max (In WA) and mines not that loud.
I dont want to rustle this womans feathers, she's threatened to call the county on me before for my "collection".
But I'm cool with the HOA and the bylaws, you cant see anything from the street. Cant wait to move out of this place and to somewhere I can build a shop, with neighbors that are more than a few hundred feet away.

Any more questions about this, please PM me.
I want to keep the thread uncluttered.

#16 987687

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Posted 08 August 2011 - 01:51 PM

WOW!!!***Amazingly good work.
I know how hard it is to polish glass like that and have it come out nicely.
Those look awesome and I can only imagine the output is much better compared to the awful stock lights.

#17 Turbone

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Posted 18 August 2011 - 12:36 AM

Ok, got some pics at night. Not the greatest, the pics dont do them justice.

Low beams.
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Hi beams.
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And up against white tarps of my canopy.
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I need to fine tune the adjustments yet.

#18 Subarutex

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Posted 18 August 2011 - 01:25 AM

Sick!

SOOOOO stoked!

:headbang:

#19 Cyfun

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Posted 09 January 2012 - 03:13 PM

Sorry to dig up a slightly old thread, but could you post a part number or something for that kit? Badly needing a headlight upgrade here. Was considering doing a DL quad headlight swap but cant find a donor car.

#20 Turbone

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Posted 09 January 2012 - 08:51 PM

http://motors.shop.e...4506.m270.l1313

These look like the ones I have.
http://www.ebay.com/...#ht_2384wt_1159

I didnt buy them off ebay tho, I got them from another board member.

Edited by Turbone, 09 January 2012 - 08:59 PM.


#21 shortysayhi

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Posted 09 January 2012 - 09:27 PM

Say i had the lights, and projectors. What would be a rough estimate of what you would charge to do the conversion?

#22 Turbone

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Posted 10 January 2012 - 09:10 AM

Around $100......if the glass doesnt crack.
Theres a risk when grinding and polishing.

#23 Cyfun

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Posted 10 January 2012 - 01:47 PM

Ah I see. For some reason I thought the eBay kit included the whole rectangular reflective piece, but that must be the original reflector from the GL headlight. How did you cut out the hole to fit that projector through?

#24 Turbone

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Posted 10 January 2012 - 02:05 PM

No need to, the end of the projector fits right thru the stock opening.

#25 Caboobaroo

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Posted 10 January 2012 - 09:19 PM

I have some headlights and can probably pick up some projectors....

:grin:




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