Contour Enthusiasts Group Archives Forums Modifications Aesthetics Projector Headlight Proto

As I had promised I'm working on creating my own set of headlights to mount projectors in. I'm growing tired of waiting for Morettes as are a lot of people I'm sure. Thanks to one of our own (Berkel) I have a set of donated headlights to work from. I most likely will need another driver side headlight because the one he sent me had the lense cut completly off so that tabs on the lense cover were not present. The idea is to make a fiberglass replacement for the actual lense and do some modifications to the factory housing. Anyway here is my first crack at what I am thinking of doing. Looking for opinions. I think I may end up turning one of the parking lights more cockeye'd to the right (left for passenger side) so when making a turn the blinker is seen by on coming traffic in that direction. This is something I just put together in about 45min so it's not a perfect match of our headlights, but you get the idea. Enough talk here are the pics:

I was wondering where this project went. So you're going to be using fibreglass? That sounds interesting, I'll get right to it, is it feasible and affordable to have this done? Is this a DIY thing? Btw, keep up the good work,

I recommend using 90mm Hella assemblies. Easy to work with and VERY good quality units.

Very interesting! All I can say is good luck because the way our headlights are set up, its really hard to get creative in there and make stuff fit.

If you are doing all that work on a customized headlight like that, then dont go with Hella 90mm. You should go with more of a Valeo or Stanley (TSX) projector yet using the hella 90mm in ur highs. Or you can go bi-xenon using just one projector, there are endless possibilities..

I thought about a similar project when i was doing my headlights...it was more of an extension of the fiberglass eyelids that were produced for our cars. Just overlay a thin layer of fiberglass over the stock lense...let it cure, then reinforce from the back. Then use the Hella 90mm which are a fully sealed and weather proof unit and you wouldn't even need the back of the housing. Create some brackets that mate the Hella high and low to the 3 mounting points on the car, as well as to a sealed turn signal unit (aftermarket LED would be perfect)...then figure out a way to secure the fiberglass front to the car... and that pretty much sums it up. The catch is that you would need to introduce a curved recessed area underneath where the projector sticks out from the fiberglass surface so that it flows around the projector lense...but that can be done after.

Goodluck Sorry about the other headlight

I can't wait to see progress on these bad boys

You will HAVE to use hella 90mm's. They are the only truley sealed projector available. otherwise, you wont be able to use fiberglass.

Good luck It's always nice to see someone trying something different, which is why I went with a Bosch projector instead of the 'tried and true' hella 90's.

Just make sure you can keep things the same on both sides

People gawked at the 1k+ price tag of projectors milan was offering, but had no idea what was involved. If half of the people that said they were too much would have tried it themselves they would realize what all is involved.

When I build headlights for people, it ends up being 1k+ also, but more then half of that is built into supplies and parts.

I cant imagine this whole thing would be 'easy' for you to set up, so I dont see 100$ being feasible. You may think it is, but after the 3rd set or so you're going to hate yourself