Projector Headlight Build

[Andrews99contour]

This is my first time attempting this, and i plan on making these adjustable by mounting them to the chrome piece in the headlight so they wont have to be perfectly in place when sealed.

i started off with a set of broken mercury cougar headlights from the junkyard

cracked them apart to get to the projector

They have alright fitment, but i have some experimenting i want to do to make a shroud around the projector.

i watched online that you can bake an acrylic sheet and slam it onto were you want to form and it hardens around whatever you want it to cover, then you just cut it for the projector to see through and glue it into place. so i'm gonna give that a try.
and yes, my headlights have to be cleared up a bit.

 

[fogartyjohn]

should be a fun project and good luck with that i just seen some in the jy yesterday and it crossed my mind maybe if they turn out good for you i will try it.

Good luck so far they look good keep us posted with the pics and progress

 

[Andrews99contour]

One other plus to this, is you can just use your contour headlight bulbs that you already have. The fit right in when I was comparing bulbs.

 

[greasemonkey1489]

Awesome! I may have to do this as well

 

[mystiquevltwin]

Looking good! How did you cut the part of the Contour headlight to get the projector to fit in?

 

[rexxdoggy]

One other plus to this, is you can just use your contour headlight bulbs that you already have. The fit right in when I was comparing bulbs.

I was thinking, why would I want to use Cougar projector lights. If I did this, I'd want some really good ones. Then you said this statement. Totally down for that. Rather not have to mess with any kind of mix and match with bulbs and wiring and whatever.

 

[Andrews99contour]

Looking good! How did you cut the part of the Contour headlight to get the projector to fit in?

I just used a drill and put one of those hole saw attachments on the end that was around the same size, then drilled out with a dremel for better fitment.

 

[fogartyjohn]

i was gunna ask that same question do u happen to know what size hole saw bit it was?

 

[Andrews99contour]

i was gunna ask that same question do u happen to know what size hole saw bit it was?

it was a 3 inch/76mm bit. it wont fit because its a tad bit to small when you drill it out so you will have to grind it down to make it fit in there snug.

 

[fogartyjohn]

thanks man
can not wait to see when this is done i like how it still looks kinda stock if you dont hightower the lights

 

[Andrews99contour]

thanks man
can not wait to see when this is done i like how it still looks kinda stock if you dont hightower the lights

this is kind of my test set which will most likely go on my daily driver. if i get it to work i want to make another set for my black svt and hightower that set black. but we will see.

 

[fogartyjohn]

yeah sure ether way i like the concept i will be watching and doing this shortly myself

 

[DuratecDave]

Do all Cougars have these exact same lamps? Also, are the high and low beam lamps the same units? Nice work thus far and thank you.

 

[Andrews99contour]

Do all Cougars have these exact same lamps? Also, are the high and low beam lamps the same units? Nice work thus far and thank you.

The cougars came with either one projector or quad projectors. So you have to find the quad set. And the high beam and low beam are the same except the low beam has a metal shield inside covering half the projector for less light output due to it being the "low" beam.

 

[greasemonkey1489]

The metal shield is called the cut-off. It only lets half of the intense, reflected light pass through the lens

 

[Chas]

How is the quality of the Cougar lenses compared to the Acura TSX ones that a lot of people have used?

 

[freakin_crazy33]

nice ill be keeping an eye on this thread also, ty much

 

[lor3nzo]

how much did you pay for those headlights?

 

[Andrews99contour]

how much did you pay for those headlights?

i paid $40 a piece because they were damaged and i said i was just getting them for the internal parts. one junkyard i went to wanted $70 a piece. it all depends on the condition and where you go.

 

[Redeemer]

You gonna throw some angel eyes on them? Well your next set if these turn out right.