About to start new bugeye headlight project

brcewane · 03-16-2006, 08:46 AM

Well I've started to acumulate all the parts that I need for my custom headlight project that I am about to embark on. I'm going to make sure that I update this thread with the progress that I make so if anyone else feels adventurous they can join in the fun on their own.

So far I have the following:
- Spare Bugeye headlight lense cover
- Spare Bugeye amber headlight turn signal cover
- Cheap $199 halo projector headlights from ebay..

Generally the final project will be a combination of these different styles:

As you can see these ebay lights will allow for the stock Bugeye lenses to fit over top of them to give the STi look.. however the the top area is for the signal light area much like the Koji/painted stock headlight mod.

So basically I am going to modify the 2 projector cylinders to seem more like the STi headlights instead of the WRC type of headlight.. so you will see the cylinder tubes for the projectors much like the STi lights.

As you can see, the cylinders are there on the ebay lights, it is just a matter of exposing them and molding them with the rest of the headlight to give it more of a 3D interior like the STi light:

I will be removing the IMO cheesy white/clear cover on the ebay lights, mold over the holes left by them and glueing the stock Bugeye amber signal cover over the turn signal. Also modifying that area a bit more to flow with the molding being done on the projectors.

At the end I think I will paint them a gunmetal with metalic fleck so they look black from a distance, but gunmetal up close. Also paint the inside of the projector cylinders with chrome paint and hook up the halo's to the parking lights.

It should be an interesting project carving up these lights...

To be continued....

Tim

* Registered users of the site do not see these ads.

brcewane · 03-16-2006, 08:57 AM

Well I now have all the parts that I need and I have started the process.. I have posted up some pics of the headlight unit and its parts plus some of the first cuts so you can kind of get the idea of where I am heading with it.

Hank3 · 03-16-2006, 09:59 AM

Cool - hope it works out for ya. In anycase, kudos for trying something new. Are you going to at least retro some quality projector units into the lights?

brcewane · 03-16-2006, 10:04 AM

Don't know about retro fitting some other projectors in there or not yet.. going to see what the light output is with some Xenon bulbs or silverstars...

Might end up putting in a HID kit into them.

bahboy20 · 03-16-2006, 10:08 AM

what brand projectors came with the lights, not valeo are they?

dan

brcewane · 03-16-2006, 10:50 AM

Quote:

Originally Posted by bahboy20

what brand projectors came with the lights, not valeo are they?

dan

no idea.. haven't really even looked at them closely yet

ptirmal · 03-16-2006, 12:26 PM

good luck, keep us updated... I would paint the black another black, maybe something more glossy, it looks kinda dull how it is now

Mulder · 03-16-2006, 12:31 PM

If you aren't going to replace the lighting units themselves, you will end up with a set of nice-looking lights with horrible lighting performance. The beam pattern of those projectors has been reported to be awful, and the reflectors are just as bad.
IMO this is only worth doing if you retrofit some quality lighting modules. And whatever you do, please do not put HIDs in those things, it will only make the situation far worse.

ptirmal · 03-16-2006, 01:44 PM

yea dont put a kit in without real hid projectors... I havent seen the halogen performance first hand but it's supposed to be worst than stock, a worthy upgrade would be at least replace the projectors (low beam) with halogen projectors off ebay (oem from a decent car, audi saab, etc) or hidplanet (fog projectors)... itll produce a decent beam for low beam projectors

Hank3 · 03-16-2006, 02:09 PM

Quote:

Originally Posted by Mulder

If you aren't going to replace the lighting units themselves, you will end up with a set of nice-looking lights with horrible lighting performance. The beam pattern of those projectors has been reported to be awful, and the reflectors are just as bad.
IMO this is only worth doing if you retrofit some quality lighting modules. And whatever you do, please do not put HIDs in those things, it will only make the situation far worse.

I was trying to take the subtle approach

eurospek · 03-16-2006, 02:54 PM

Nothing will ever top the hotness of the original, there is just no way!

brcewane · 03-16-2006, 03:18 PM

^^ you are right... but this is better than a kick in the nuts from my wife if I spend $1000 US on the STi projectors

abosworth · 03-16-2006, 03:22 PM

Quote:

Originally Posted by brcewane

^^ you are right... but this is better than a kick in the nuts from my wife if I spend $1000 US on the STi projectors

TygerStile · 03-16-2006, 03:30 PM

good luck with the project.

Psipwrd · 03-20-2006, 05:31 AM

susbcribed

Lexington · 03-20-2006, 11:31 AM

I did something similar to this...

I took hella 90mm projector modules and grafted them into the ebay lights, then I painted the whole housing to match.

I liked it, had great light output, but I just like the look of the JDMs better.

Handsdown · 03-20-2006, 11:36 AM

yeah, for 120 bucks said and done, the hella H9 projectors are beyond 'worth it'.

they put out 2100 lumens with the same life as normal bulbs, and the hella projector's optics are industry standard. the projectors you have currently have TERRIBLE beam patterns, if you do a side by side comparison you can see how bad the beams are. i remember seeing a picture of it but can't find it now.

this looks promising, but you'd be a fool to spend the 200+ DIY materials and the hours and hours of time without spending the extra 120 to get GOOD lighting out of it.

KAX · 03-20-2006, 12:28 PM

make sure you do a better job sealing it then this guy

otherwise, your efforts wont be worth it.

and ditto on the changing projectors to HID based with real HIDs.

Sylon · 03-20-2006, 12:31 PM

Wow, halo's in a bugeye, good luck with that! I'm no electrician, I would be bound to mess something up, good luck, I wanna see how that turns out!

imprezive one · 03-20-2006, 12:42 PM

I like your vision, interested to see how this turns out.

brcewane · 03-20-2006, 01:17 PM

Yeah.. I'm looking into those hella projectors.. maybe move the angel eye from the ebay ones to the hella one

I've found a few sites that sell them.. does anyone have a place with good prices that they have done business with??

brcewane · 03-20-2006, 01:41 PM

Quote:

Originally Posted by Lexington

I did something similar to this...

I took hella 90mm projector modules and grafted them into the ebay lights, then I painted the whole housing to match.

I liked it, had great light output, but I just like the look of the JDMs better.

got any pics?

brcewane · 03-20-2006, 01:57 PM

Did a little bit more cutting this weekend... It is still freaking cold outside so the fingers can only take so much.

I have to do some more trimming of the upper area around the turn signal and then I should be able to fiberglass in the top. Need to do that first so that I have the support to cut out the area below the projectors marked in the green tape.

I'll be trimming down the cylinder on the outside that holds the projector to give a more staggered look like the JDM headlights as well. Just need that fiberglass work first to hold them in place.

Enriched · 03-20-2006, 07:22 PM

very interesting definetly subscribed

hikeeba · 03-20-2006, 10:37 PM

Very interesting. I can't wait to see more progress. 10 for originality.

03-16-2006, 08:46 AM	#1
brcewane Scooby Specialist Member#: 63990 Join Date: Jun 2004 Location: Ontario Vehicle: 2002 WRX Flat Grey	About to start new bugeye headlight project Well I've started to acumulate all the parts that I need for my custom headlight project that I am about to embark on. I'm going to make sure that I update this thread with the progress that I make so if anyone else feels adventurous they can join in the fun on their own. So far I have the following: - Spare Bugeye headlight lense cover - Spare Bugeye amber headlight turn signal cover - Cheap $199 halo projector headlights from ebay.. Generally the final project will be a combination of these different styles: As you can see these ebay lights will allow for the stock Bugeye lenses to fit over top of them to give the STi look.. however the the top area is for the signal light area much like the Koji/painted stock headlight mod. So basically I am going to modify the 2 projector cylinders to seem more like the STi headlights instead of the WRC type of headlight.. so you will see the cylinder tubes for the projectors much like the STi lights. As you can see, the cylinders are there on the ebay lights, it is just a matter of exposing them and molding them with the rest of the headlight to give it more of a 3D interior like the STi light: I will be removing the IMO cheesy white/clear cover on the ebay lights, mold over the holes left by them and glueing the stock Bugeye amber signal cover over the turn signal. Also modifying that area a bit more to flow with the molding being done on the projectors. At the end I think I will paint them a gunmetal with metalic fleck so they look black from a distance, but gunmetal up close. Also paint the inside of the projector cylinders with chrome paint and hook up the halo's to the parking lights. It should be an interesting project carving up these lights... To be continued.... Tim * Registered users of the site do not see these ads.

03-16-2006, 10:08 AM	#5
bahboy20 Scooby Specialist Member#: 6726 Join Date: May 2001 Location: DC/MD/VA Vehicle: 2002 PSM	projectors what brand projectors came with the lights, not valeo are they? dan

Thread Tools
Show Printable Version Email this Page
Display Modes
Linear Mode Switch to Hybrid Mode Switch to Threaded Mode

Similar Threads
Thread	Thread Starter	Forum	Replies	Last Post
Nj Fs Brand New Bugeye Headlights	ShadowRex86	Exterior/Styling	0	01-26-2008 07:31 AM
About to embark on my suspension project, need some advice	dauss	Brakes, Steering & Suspension	8	04-26-2007 01:10 PM
An open letter to those about to start a "Goodbye" thread.	teh Phil	Off-Topic	1	06-30-2006 08:24 AM
So if I were to start a type RA project on my car I would...	gc822	General Community	14	01-15-2006 12:41 AM
whats a good base engine to start a big hp project?	dubaru	General Community	25	09-10-2004 03:11 AM

03-16-2006, 08:57 AM	#2
brcewane Scooby Specialist Member#: 63990 Join Date: Jun 2004 Location: Ontario Vehicle: 2002 WRX Flat Grey	Well I now have all the parts that I need and I have started the process.. I have posted up some pics of the headlight unit and its parts plus some of the first cuts so you can kind of get the idea of where I am heading with it.

03-16-2006, 09:59 AM	#3
Hank3 Scooby Guru Member#: 16157 Join Date: Mar 2002 Chapter/Region: South East Location: Tallahassee, FL Vehicle: '03 Mazda P5 <>< '02 WRX & '08 MS3 SOLD!!!	Cool - hope it works out for ya. In anycase, kudos for trying something new. Are you going to at least retro some quality projector units into the lights?

03-16-2006, 10:04 AM	#4
brcewane Scooby Specialist Member#: 63990 Join Date: Jun 2004 Location: Ontario Vehicle: 2002 WRX Flat Grey	Don't know about retro fitting some other projectors in there or not yet.. going to see what the light output is with some Xenon bulbs or silverstars... Might end up putting in a HID kit into them.

03-16-2006, 12:26 PM	#7
ptirmal Scooby Specialist Member#: 82243 Join Date: Mar 2005 Chapter/Region: Tri-State Location: Philly Vehicle: 13' BMW X3 35i	good luck, keep us updated... I would paint the black another black, maybe something more glossy, it looks kinda dull how it is now

03-16-2006, 12:31 PM	#8
Mulder Trust no one Moderator Member#: 11170 Join Date: Oct 2001 Chapter/Region: Tri-State Location: NYC Vehicle: 02 RAV4 MT 15 WRX/11 CRZ	If you aren't going to replace the lighting units themselves, you will end up with a set of nice-looking lights with horrible lighting performance. The beam pattern of those projectors has been reported to be awful, and the reflectors are just as bad. IMO this is only worth doing if you retrofit some quality lighting modules. And whatever you do, please do not put HIDs in those things, it will only make the situation far worse.

03-16-2006, 01:44 PM	#9
ptirmal Scooby Specialist Member#: 82243 Join Date: Mar 2005 Chapter/Region: Tri-State Location: Philly Vehicle: 13' BMW X3 35i	yea dont put a kit in without real hid projectors... I havent seen the halogen performance first hand but it's supposed to be worst than stock, a worthy upgrade would be at least replace the projectors (low beam) with halogen projectors off ebay (oem from a decent car, audi saab, etc) or hidplanet (fog projectors)... itll produce a decent beam for low beam projectors

03-16-2006, 02:54 PM	#11
eurospek Scooby Guru Member#: 96944 Join Date: Sep 2005 Chapter/Region: MWSOC Location: Hampshire, IL Vehicle: 2005 SAAB 9-2X AERO 4eat Stage 2 Protuned	Nothing will ever top the hotness of the original, there is just no way!

03-16-2006, 03:18 PM	#12
brcewane Scooby Specialist Member#: 63990 Join Date: Jun 2004 Location: Ontario Vehicle: 2002 WRX Flat Grey	^^ you are right... but this is better than a kick in the nuts from my wife if I spend $1000 US on the STi projectors

03-16-2006, 03:30 PM	#14
TygerStile Scooby Specialist Member#: 14531 Join Date: Jan 2002 Chapter/Region: SCIC Location: SfVoltron-SoCal Vehicle: 02' Stage4 wrb WRX 06' Mazdaspeed6, 85' AE86	good luck with the project.

03-20-2006, 05:31 AM	#15
Psipwrd Scooby Specialist Member#: 102746 Join Date: Dec 2005 Chapter/Region: SWIC Location: Aviano AB, Italy Vehicle: 1992 Celica GT-4 CS Black	susbcribed

03-20-2006, 11:31 AM	#16
Lexington Scooby Guru Member#: 50221 Join Date: Dec 2003 Chapter/Region: MWSOC Location: Near water Vehicle: I'm on internets Racin on ur bandwidth!	I did something similar to this... I took hella 90mm projector modules and grafted them into the ebay lights, then I painted the whole housing to match. I liked it, had great light output, but I just like the look of the JDMs better.

03-20-2006, 11:36 AM	#17
Handsdown Scooby Guru Member#: 29355 Join Date: Nov 2002 Chapter/Region: NWIC Location: seattle	yeah, for 120 bucks said and done, the hella H9 projectors are beyond 'worth it'. they put out 2100 lumens with the same life as normal bulbs, and the hella projector's optics are industry standard. the projectors you have currently have TERRIBLE beam patterns, if you do a side by side comparison you can see how bad the beams are. i remember seeing a picture of it but can't find it now. this looks promising, but you'd be a fool to spend the 200+ DIY materials and the hours and hours of time without spending the extra 120 to get GOOD lighting out of it.

03-20-2006, 12:28 PM	#18
KAX Scooby Specialist Member#: 63292 Join Date: Jun 2004 Chapter/Region: South East Location: Warner Robins, GA Vehicle: 2000 Subaru 2.5RS 2002 WRX powered	make sure you do a better job sealing it then this guy otherwise, your efforts wont be worth it. and ditto on the changing projectors to HID based with real HIDs.

03-20-2006, 12:31 PM	#19
Sylon Scooby Specialist Member#: 109000 Join Date: Mar 2006 Chapter/Region: International Location: The land of the Nurburgring Vehicle: 2006 Impreza 2.5i Obsidian Black Pearl	Wow, halo's in a bugeye, good luck with that! I'm no electrician, I would be bound to mess something up, good luck, I wanna see how that turns out!

03-20-2006, 12:42 PM	#20
imprezive one Scooby Specialist Member#: 16906 Join Date: Mar 2002 Chapter/Region: MWSOC Location: Cleveland to Columbus Vehicle: 2k3 wrx wagon PSM	I like your vision, interested to see how this turns out.

03-20-2006, 01:17 PM	#21
brcewane Scooby Specialist Member#: 63990 Join Date: Jun 2004 Location: Ontario Vehicle: 2002 WRX Flat Grey	Yeah.. I'm looking into those hella projectors.. maybe move the angel eye from the ebay ones to the hella one I've found a few sites that sell them.. does anyone have a place with good prices that they have done business with??

03-20-2006, 01:57 PM	#23
brcewane Scooby Specialist Member#: 63990 Join Date: Jun 2004 Location: Ontario Vehicle: 2002 WRX Flat Grey	Did a little bit more cutting this weekend... It is still freaking cold outside so the fingers can only take so much. I have to do some more trimming of the upper area around the turn signal and then I should be able to fiberglass in the top. Need to do that first so that I have the support to cut out the area below the projectors marked in the green tape. I'll be trimming down the cylinder on the outside that holds the projector to give a more staggered look like the JDM headlights as well. Just need that fiberglass work first to hold them in place.

03-20-2006, 07:22 PM	#24
Enriched Scooby Newbie Member#: 100178 Join Date: Nov 2005 Chapter/Region: MAIC	very interesting definetly subscribed

03-20-2006, 10:37 PM	#25
hikeeba Scooby Specialist Member#: 89165 Join Date: Jun 2005 Chapter/Region: MWSOC Location: SE WI Vehicle: Poop Stuck Survivor -=C=- & subari87 FOREVER!	Very interesting. I can't wait to see more progress. 10 for originality.