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Since I got a couple requests for a write up, here it is. I do lack pictures for most parts though since I wasn't organizing for a write up unforutnately.

1) Allign the GTS clears and stock lens to decide where to cut out the stock lens. i left aruond half a cm all around on the front face for glueing.

2) Cut out the front face of the stock lens now that we've determeined where to cut. It'll look soemthing like this. I wasn't worried about smooth cutting since I planned on painting a black trim at the first place.

<img src="http://members.rogers.com/aishi/clearle ... plant2.jpg" alt=" - " />

3) Glue the GTS clear over the cut out. I used Goop's marine glue/sealant since thin/hard glue gave me some concerns with the two material dont' expand at the same rate when heated and stress or seperate might occur at the seam. Thick gooey glue will provide some padding when there's a slight offset due to thermal expansion. Process of glueing:

<img src="http://members.rogers.com/aishi/clearle ... plant1.jpg" alt=" - " />

4) More glue is rubbed into the cracks to complete waterproofing. Good glueing will allowing the lens to hold water in the "bowl" without letting any out from the seam.

5) For reinforcement and partialy cosmetic reasons I used bondo to join up the edge of the GTS lens to the stock lens. At this point I decided to cut the pull-over tab on the top of the GTS lens off.

6) For cosmetic reasons I decided to paint a black trim on the outer edge of the GTS to hide the glue. (both outside and inside). Masking is very important!!! A few speckles from the paint can be rubbed off with some acetone but when too much gets onto the lens it's game over and back to square one for us.

What the lens looks like now:

<img src="http://members.rogers.com/aishi/pictures006.jpg" alt=" - " />

7) I'm planning on putting an xpel film over the lens since GTS's acrylic seems a lot flimsier than the stock lexan ones.

Having said that any suggestions, comments and opinions welcome.

Cheers,

Eugene

very nice!

a suggestion. paint that side housing that's unused to black. i did that and trust me, you won't regret it

im sorry i doubted, that is awsome man

very nice !

Hey Eugene, those look great. I would paint inside black or grey. This way you will also avoid HID reflection from the bottom of the headlight upwards. Also, get rid of that GTS logo.

I forgot how nice those FF50's look in there. Why did I choose a harder way?

Originally posted by JDM:
I forgot how nice those FF50's look in there. Why did I choose a harder way?

It's not the harder way, it's the better way! When you post your beam pics I'll drool all over my headlights.

Thanx for the compliments btw.

I'm doing some temperature stress testing on the lend as we speak, just leaving the ff50 on (since i can do it with a car charger in my room) for over 20min now and see if the lens turns into soup. So far so good (knock on wood).

Here's how things look now, GTS logo still has to go



Cheers y'all!

Eugene

bada** looks so awesome! i cant wait to see them installed and a cf hood too!! great job and how-to mang

Very nice. Looks great. You are right about blacked out headlights like that. Less attention.....until you turn those suckers on.

Make sure you align your FF50's with those Hellas before you seal them up. 2.1" inch drop for low beams for each 25'. I actually did my H9's a bit higher than that, just in case I wish to lower my lights a bit. Bi-xenons are good enough though, but H9's would be bun to flash with.

<small>[ June 15, 2004, 03:34 AM: Message edited by: JDM ]</small>

Originally posted by Eugene H.:
Still open for comments and suggestions.

Off topic: Taras I got my cf hood today, you're next

Cheers y'all!

Eugene

I think a small LED marker light will fit just nicely on the outer side of those Hellas. Sorry, just giving you more of my useless ideas.

Yeah, can't wait for my hood....

Originally posted by JDM:
I think a small LED marker light will fit just nicely on the outer side of those Hellas. Sorry, just giving you more of my useless ideas.

Your idea's not useless at all!
I've thought of using those aftermarket side markers I happen to got for free as city lights (is that what theyr'e called? the little light bulbs in the new vw's) and hope they're bright enough to be day time runners. (even dimmed ff50 might hurt people I think)

Still have to brainstorm on this a bit.

Eugene

Intersting... I have been following your progress and would like to know how well those things hold up to the heat that those projectors will throw out.

Keep us updated...

Also-- Where did you get those covers?? I thought they weren't being made anymore??

Originally posted by atlantamx3:
Intersting... I have been following your progress and would like to know how well those things hold up to the heat that those projectors will throw out.

Keep us updated...

Also-- Where did you get those covers?? I thought they weren't being made anymore??

I did a short stress test with the projectors (high beam (ff50 since it was a lot closer to the lens than the bixenon) on for 30 min) and the lens was fine. Doing the same test with bixenons will be more troublesome. Still have to make sure it can handle both lights being on

Eugene

im sure the lens will cool down as well while driving the car (via incoming air hitting the front end)

You do have a good point...That's actually one of my concern...when I'm driving around in winter the headwind will be at something in the vicinity of -40oC and the light will be as hot as it should be. The drastice difference at the two sides of the lens might cause a lotta stress (I calculated 23mil/in/in of expansion)

This is the part where I won't get to test before I finalize the project and I'm hoping for the best Knock on wood.

Until then, the headwind will be on my side

Eugene

my queston is how to you replace the bulbs when they go?