Flush Headlight Conversion

[H22AccordSE-IV]

What's up Y'all?
Since I crunched the right side of my HL assembly 2 years ago, I've been working on a flush HL conversion. It's still in progress and I've come pretty far in getting it completed, but time has been an issue for me. Here's an update of progress so far (Many of you guys may have seen my PS ideas in my thread titled "H22A swap completed and running!"). The pictures are from my camera phone so sorry guys, they may not be the greatest...

Lights Used: 90mm Hella high/low beam headlight modules for custom applications.

Where's the Beef?
http://img176.imageshack.us/img176/5338/11xf1.jpg
Here's the original bracket primed, checking fitment...
http://img237.imageshack.us/img237/5206/6tg4.jpg
http://img176.imageshack.us/img176/89/5ft5.jpg
http://img176.imageshack.us/img176/7501/8px0.jpg
http://img227.imageshack.us/img227/4570/7bv2.jpg
The original bracket was used temporarily so I could drive at night but the mounting area was too abstract to mount the high beam in on the inside of the bracket...
http://img227.imageshack.us/img227/2224/10lc8.jpg
Low beam...
http://img224.imageshack.us/img224/5691/3rq0.jpg
High beam...
http://img170.imageshack.us/img170/1453/2ks2.jpg
Both low beams...
http://img224.imageshack.us/img224/6205/4ri5.jpg
So far I have one bracket completed, but I have to get my buddy at the machine shop to cut me 2 fresh brackets. It's all about trial and error so when I mounted the new bracket I made, I noticed that the lights are sitting a half inch too high, which means I'll have to increase the size of the vertical part of the bracket by a half inch when I get the new ones cut. I will also extend the width of the bracket so it will be one piece, instead of using a smaller bracket to make the attachment to the front mount on the rad support. The extra holes in the bracket were part of the trial and error process and, originally, I didn't have the lights centered correctly so I had to re-drill the holes. As you may have noticed, the left side has the low beam on the inside and the right side w/the original pop-up bracket has the low beam on the outside. I know the standard is high on the inside and low on the outside, but I haven't decided on which way to go yet. I'll continue to keep you guys posted on the conversion. Let me know what y'all think!

Peace

G.

[Vanilla Sky]

high is on the inside for a reason. it's so you don't blind other drivers as badly if you leave them on as you pass. plus, your low beams are supposed to illuminate the area in front of the vehicle and the highs are supposed to project down the road. it's easier to project two beams into one if they're closer together.

[newaccorddriver]

nice work man, if your selling, im definetly a customer!

just curious, how did you wire it up so you have 2 separate light bulbs for the housings?

[H22AccordSE-IV]

high is on the inside for a reason. it's so you don't blind other drivers as badly if you leave them on as you pass. plus, your low beams are supposed to illuminate the area in front of the vehicle and the highs are supposed to project down the road. it's easier to project two beams into one if they're closer together.

I saw a guy's Miata with the same conversion and he had his low's on the inside. I did a PS of my finished conversion w/the lights reversed and I liked the way the projectors looked on the inside. Probably wouldn't make a diff to anyone else.
Here are some pics:
http://img223.imageshack.us/img223/4972/hwithcoversjr0.jpg

http://img81.imageshack.us/img81/8431/accordheadlightconversioncopyxy9.jpg

http://img183.imageshack.us/img183/6600/accordheadlightconversioniicopywk5.jpg

http://img218.imageshack.us/img218/827/accordheadlightconversioniiiicopyqb6.jpg

Your logic may have swayed my decision.

Thanks VS

G.

[H22AccordSE-IV]

Here's a PS'd pic of the finished conversion w/the original HL cover, cut and mounted into place. I was thinking of using a clear lexan sheet to fill in the area where the HL cover was cut. http://img218.imageshack.us/img218/4364/pshlzo9.jpg

[Vanilla Sky]

i don't like it cut there. it cheapens the whole look. you should just cut where the trip peice sat, and then cut bumps for the lights themselves. that's the cleanest way i can think of.

[H22AccordSE-IV]

nice work man, if your selling, im definetly a customer!
just curious, how did you wire it up so you have 2 separate light bulbs for the housings?
When I get the project finished, I will try to make it available as a kit for anyone who wants to buy.

Your OEM pop-ups use a High/low sealed beam; You've probably noticed (if you've ever changed or replaced your lights) that the lighting system incorporates 3 wires running into the socket; a negative, low-beam power, and high-beam power. I simply ran the power wires individually into to the corresponding high and low beam sockets, then bridged the negative wire to run separately into both.

G.

[ChaseR]

I don't like it, I think that the original pop ups would have been better. If I were to go fixed lights I would use the Euro style that was availiable at the time...

[Acid X]

Seems interesting. Lets see how the finished product looks. :)

[carotman]

Nice work, but you shoul definetly put the lows on the outside. This is required by Law in Canada. :D

[mkymonkey]

looks cool...but the grill makes it look weird. but its an awesome idea. i think youre the second one to try this. not sure though.


anyway good luck bud!

[H22AccordSE-IV]

I appreciate all your comments guys, positive or negative, keep 'em comin'.

Hey Monkey, what did you mean by "the grill makes it look weird"? Did you mean the lack of a grill? Do you think it would look better with the original grill?

[mkymonkey]

i actually like it without the grille. with the grill it would look weird. im pretty sure youre going to intergrate something to make it blend in more...........right? lol other than that it looks good. of course its your car and this is just my opinion you can take it or not...the car would still be unique

[reanimator420]

you should make the fill in the space where the flip light use to be

[gfrg88]

what about doing that but still making them pop up?? :D

[ghettogeddy]

what about doing that but still making them pop up?? :D
thats what i want a duel light setup i even have the wiring for it

[newaccorddriver]

i remember seeing this kind of thing on an RX7 once at a car show, i always thought it came in some sort of a kit, not something you slap together yourself. you sir, are a true pioneer :)

[AccordEpicenter]

im personally a flipup fan but this is the best attempt at fixed lights ive seen yet

[H22AccordSE-IV]

what about doing that but still making them pop up?? :D
That would defeat the purpose of constructing a flush HL conversion, wouldn't it? I mean i could have just mounted the Hella lights on to the pop-up assembly (hey, that just made me think of a car I saw about a week ago in my parking lot; a newer model Ford Probe in my visitor's parking had the same Hella lights mounted into its pop-up assembly...looked pretty sick!)but I don't think it would make it as unique. I wanted to try something completely different.

i remember seeing this kind of thing on an RX7 once at a car show, i always thought it came in some sort of a kit, not something you slap together yourself. you sir, are a true pioneer :)
Thanks, NAD.


i actually like it without the grille. with the grill it would look weird. im pretty sure youre going to intergrate something to make it blend in more...........right? lol other than that it looks good. of course its your car and this is just my opinion you can take it or not...the car would still be unique
What did you have in mind about integrating the grill and the new assembly? Give me some suggestions...

[ghettogeddy]

how much were those hella lights and what kind of bulbs do they take

[L3G10N]

i want some!!!!

[H22AccordSE-IV]

how much were those hella lights and what kind of bulbs do they take
The lights were about $90 CAD a piece, and use an H9 bulb (still waiting for an aftermarket HID set) which is included.

[ICEMAN707]

H22Accord, that looks exactly what I've done with my projector headlight conversion. I made a similar metal bracket and made fiberglass housings painted black to clean it all up. Now I'm just trying to get some plexiglass bent right, the same as the original metal cover, to cover it all up. If I get it too hot with the heat gun, air bubbles show up. But good luck with yours bro. Keep up the good work!

[H22AccordSE-IV]

H22Accord, that looks exactly what I've done with my projector headlight conversion. I made a similar metal bracket and made fiberglass housings painted black to clean it all up. Now I'm just trying to get some plexiglass bent right, the same as the original metal cover, to cover it all up. If I get it too hot with the heat gun, air bubbles show up. But good luck with yours bro. Keep up the good work!
Already tried that with Lexan over the original cover...heat bubbles, fogging, warping, unavoidable scratches. I went through about $100 in Lexan (about 3 sheets, 2 covers a piece) and out of the 4 I attempted, 2 got really fuc*ed up. Only the last one was alright but still far from perfect.
Let me know how yours work out and give me some tips if any...I'd appreciate 'em!
Good Luck, Ice.

G.

BTW, any pics of your conversion?

[Vanilla Sky]

It takes a lot of practice to get lexan to bend without any other ill effects. I've done it before a couple times with good results. It just takes practice. Get yourself some scrap and have at it again. Keep the temp on low.

[ICEMAN707]

HERE'S MY IDEA: I'm gonna strip off the paint on my metal covers. Preheat my oven for 350 degrees. Lay plexiglass over the metal over. Put in oven. Make sure you watch it for 10 mins, remove as soon as the plexi melts and forms the shape of the metal cover. Make sure not to get it too hot though or the plexi will stick. Cooking spray on the metal cover should help. Just get it hot enough to melt it to shape.

ANOTHER IDEA: Instead of messing with plexi, just make it completely "sunken in". Close off/shave off the part of the metal cover where the eyelids used to go, cut 2 holes about the same diameter as the lights, cus 2 sections of PVC pipe about the same diameter as the lights to use as "tunnels" for the lights, paint the insides of the pipe black, and viola!

HERE'S ANOTHER COOL PIC IDEA:

http://www.pauldesign.ru/honda/photos/bodykit/nopopup08.jpg

[HondaBoy]

i had been working on a dual projector setup, but i havent done much to them so far. here's the link.
http://www.3geez.com/forum/showthread.php?t=52990&highlight=projector

[ICEMAN707]

I was gonna try the stealth/3000gt projectors too but they were too expensive to buy just to experiment on. So I'm opting for a cheaper start first and see how that goes. One of us is bound to come up with something soon. Good luck to the both of you! It's nice to hear other people having the same ideas as me. :rockon:

[HondaBoy]

hopefully i can finish up on mine. they need to be set in the braket so i can make some surrouding panels. i hope to get an HID low beam it. but at first i'm just going to use what i have for it.

[ICEMAN707]

Here's what I found on the net....I guess I'm right on the oven trick...but it's 250 degrees, not 350 like I mentioned, for 5-10 mins...and a cotton flannel cloth sheet as a release agent:

BASIC HEAT FORMING

Remove the masking paper before any heat forming operation. When you put the plexiglass in the oven, never lay it on a bare metal tray, rack, or form, as that will result in "mark-off" areas. Your wood or plaster forms should be prepared by covering them with cotton flannel cloth. Avoid excessive or prolonged heating of the plexiglass. For simple forming operations, preheat the oven to about 250 degrees F and slip your mold and all into the oven. Heat it for 5 minutes or until the plexiglass droops and limply embraces the form. Remove the form and plexiglass from the oven, and using cotton gloves, make sure that the plexiglass stays snugged down around the form as the acrylic piece cools. Do not remove the plexiglass from the form until it has cooled below 175 degrees F. All acrylic sheets will shrink approximately 2% when heated, therefore if there is a requirement for a dimensionally accurate piece, it might be best to make the piece slightly oversize, and later trim it to the exact dimensions


http://www.solanopilots.com/images/Image10.gif

I'd be leary about the cotton cloth though, sounds dangerous to have that in an oven...lol. I'd just use some car wax on the metal cover as a release agent instead.

[ICEMAN707]

My Projector Headlight idea is something like this :rockon:


http://probeaddiction.com/images/Halo%20Eyes.gif

[mkymonkey]

imo...molded like the pic iceman posted above would look sick. though it probably be hard to make it blend in nicely with our boxy accords lol

[ICEMAN707]

It's really not that bad. Here's an example of something similar on a friend's NSX, and the NSX has sharp lines like our 3geez:



http://myspace-183.vo.llnwd.net/00996/38/15/996605183_l.jpg

[mkymonkey]

yeah but dont they make kits for the nsx already. im saying it would be hard to make it look good lol. plus the nsx's styling still looks brand new. you could pass that as an 07 if you were talking to a retard haha

[gfrg88]

yeah but dont they make kits for the nsx already. im saying it would be hard to make it look good lol. plus the nsx's styling still looks brand new. you could pass that as an 07 if you were talking to a retard haha

:huh: i thought it was an 07?

[mkymonkey]

um....lol are you serious? haha

[Xtreemjedi]

I've been trying to figure out what to do with my headlights, I just don't like the way they look. This looks really good. Has anyone thought about having the headlight cover come OVER the HL conversions? That would eliminate the need for trying to get that perfect shape with the plexi, and when you have them closed, it looks stock.

[stat1K]

personally i think the whole idea is a little dumb. i like the flip up headlights and making it not flip up just makes me think of a 4g... something which i scorn. but as for molding the plexiglass... you don't need to worry about the cotton because cotton is very similar to paper in that it burns at higher temperatures. 410 degrees fahrenheit to be exact... paper burns at 451 not much difference. so you can heat it to 310 all you want no big deal there. the thing you would have to watch is whether or not it has any kind of other substance on it... so in other words wash it before you use it. but keep up the good work i'm anxious to see what you guys can make even though i don't really like the entire idea.

[ICEMAN707]

I've also been thinking of cutting up other car's projectors and mold them in with fiberglass to fit the 3gee headlight housings:

http://www.js-autoonline.com/pics/CarAccessories/Headlights/NewHLPix/HL_Celica0005.jpg

http://images.andale.com/f2/118/100/11257562/1139975640416_1141229148567_LH_FF00.jpg

http://www.symmicauto.com/images/auto/5393.jpg

http://images.andale.com/f2/109/113/17223907/1136442108177_LP_FF150BB_YD.jpg

http://images.andale.com/f2/118/126/16262723/1145971745364_PHL1_E34_8995_CCCC_KS.jpg

...OR even motorcycle projectors:

http://i1.ebayimg.com/01/i/07/d2/58/66_12.JPG

http://i11.ebayimg.com/05/i/07/cf/77/93_12.JPG


http://i19.ebayimg.com/06/i/08/28/ee/36_1_b.JPG

[sinisterfuzzy]

HERE'S ANOTHER COOL PIC IDEA:

http://www.pauldesign.ru/honda/photos/bodykit/nopopup08.jpg

that is insanely bad ass...


It's really not that bad. Here's an example of something similar on a friend's NSX, and the NSX has sharp lines like our 3geez:

http://myspace-183.vo.llnwd.net/00996/38/15/996605183_l.jpg

so is that.


Thanks, NAD.

and that sounds funny

[H22AccordSE-IV]

Here's an update:
Slow progress, but I just got a new plate cut and started cutting and drilling. Just need to grind the holes for the light housings smooth, chamfer a couple more adjusting holes for the gromets to snap in, prime and paint black. As you can see, I've incorporated the third mounting point (the one near the rad) in the bracket to make it all one piece, as opposed to my first design made up of two pieces - it's way cleaner this way. Here are a couple pics of the raw headlight bracket.

http://img462.imageshack.us/img462/4240/194831np6.jpg
http://img361.imageshack.us/img361/4525/194814pi9.jpg
http://img137.imageshack.us/img137/7955/195101qj3.jpg
http://img361.imageshack.us/img361/3134/195121qt2.jpg
Here you can see the third mounting point in my original design using a second, smaller bracket bolted up to the assembly - looked like ass!
http://img393.imageshack.us/img393/255/8lc7.jpg
http://img374.imageshack.us/img374/5747/6xn3.jpg

[ghettogeddy]

have u thought about making them in the pop up bucket instead of getting ride of thebucket i think it would be easyer

[H22AccordSE-IV]

Tried that. It's in the post...the original buckets are too abstract and a little too tight to mount the lights properly.

[ghettogeddy]

oh ok

[bakedboarder34]

hey this is an awesome idea, i personally think that it would be better if you put peicies of like glass or plastic, over the lights where the cover for the light would be and maybe fog it or something, or maybe make them look like the lights on the integras, that would be sweet, it would take some machining but it would be freakin sweet. the reason i said fogged plastic, because it would give it like a 3-5th gen. prelude. anyway i hope you respond to me on this because i am highly interested in this perticular research.

[MECM]

hmm intrested in seeing what it ends up looking like.

[jschatte]

So you've been driving around like that for the last 3 months? lol. I am also very interested on how this is gonna turn out. Good Luck!

[speedpenguin]

This is my post to subscribe to this thread so I can follow it. Cool project!

[H22AccordSE-IV]

Thanks for your support y'all. If you look earlier in the post, I photoshopped a cut HL cover over the two mounted lights to show you my concept for the finished product. I'm planning on trying to bend some lexan to replace the other half of the cover to close it up, just got to determine how to mount the cover itself. I tried the full lexan cover but I had problems bending with the heat gun: bubbling, fogging, warping, etc.
I've been driving like that for a lot longer than 3 months (lol); at first, I was driving with 1 projector and 1 pop-up, when I crunched my right side after a fender bender in the rain. I later changed the pop-up to another projector mounted on the original bracket, when I just started to play with the idea of a flush HL conversion.

[russiankid]

That looks really cool, but i like flip up lights. Not alot of cars know days have flip up headlights, or even older cars so this makes it unique.