Projector headlight

[Paul1965]

So I've been wondering for a long time now what it would take to install a projector headlight with an HID bulb in my FJ. Having tried just an HID with the stock lens (as many others have), I know it just scatters the light all over the place. What I had to was figure out how to replace the stock glass headlight lens with a clear one. I called at least two dozen different local businesses that do vacuum forming, and all of them wanted an arm and a leg to make a copy of my lens. So I (for the most part) followed the instructions here http://www.instructables.com/id/Make-a-good%2c-cheap%2c-upgradeable-sheet-plastic-vacu/ and made my very own vacuum table. I was more than satisfied with my very first "pull" as they call it, and started trimming the plexiglass down until I was happy with how it fit inside the fairing. Next I used some epoxy and silicone to attach the lens to the fairing. As that set up, I removed the two notches in the reflector portion of my donor housing and painted it satin black. After the paint had dried I installed the projector and added some weather stripping just to cover up the ugly groove where the Yamabond sealed the old lens up. Once the projector was installed I trimmed away the two locating tabs on the housing and bolted it up.
There is one issue I didn't plan on though, and that was to be sure of how much of the extra plexiglass I needed to trim away before securing it to the fairing. Unfortunately I didn't trim enough from the bottom of the lens, as it cracked when I bolted the housing in. However it doesn't impact the performance of the light, and since I plan on eventually making a housing that will allow two projectors to be mounted in it, I'll let it go for this year. I tried to put the pics in the order of how I did everything; let me know if you have any questions.

[movenon]

Looks good Paul. Let us know how it preforms at night time. Nice to push the mod envelop ! 
George

[Joe Sull]

If i ever look in the mirror an think there's a ufo following me, I'll have to remember It's probably just you. That's just wild looking. Reminds me of the robot in the 56 movie " the day the earth stood still" . Very cool

[Paul1965]

If i ever look in the mirror an think there's a ufo following me, I'll have to remember It's probably just you. That's just wild looking. Reminds me of the robot in the 56 movie " the day the earth stood still" . Very cool

I'll tell ya, for my first crack at it I'm quite happy with it. When I re-do things this winter I think it will look even better with the housing painted red and two 2.5" projectors stuffed inside of it. I just have to figure out how to retain the adjustment function.

[keand3]

Paul, outstanding!
This look just awesome! This what's needed to have a propper HID on the FJ..
Going for a complete projector like you have is the way to go 

Thumbs up! 

Ken

[1tinindian]

That is the cats ass!
I really think you have hit on something here.
Where did you get the vacuformer?

Leon

[Paul1965]

That is the cats ass!
I really think you have hit on something here.
Where did you get the vacuformer?

Leon

Actually I made it, and it was a lot easier than I expected. In my first post there's a link to an article on how to make it. I followed the basic instructions, except all I did was cut a 1 1/2" hole in the center and attached my vacuum cleaner directly to it. The table is nothing more than 3/4" MDF, about 20" wide and 24" long and all I did was rest it between two stools. In the oven I had just one rack in the middle, with 2 beer cans filled with water to act as the support for the frame that the plexiglass was sandwiched in. I started the oven at 250 but that wasn't enough, so I ended up at 400. Once I saw enough sag in the plastic (about 4"), I turned on the vac, pulled the frames out and plopped it on my table with the glass lens in place. The first pic I posted shows it after it had already cooled for a few minutes.

[Paul1965]

Paul, outstanding!
This look just awesome! This what's needed to have a propper HID on the FJ..
Going for a complete projector like you have is the way to go 

Thumbs up! 

Ken

Ken I knew you'd love it 

[Pat Conlon]

Very interesting Paul....Some questions...

On your planned future dual setup, will they be side by side or vertical?

At speed, the wind pushing against the plexiglass lense can be substantial, does the housing support the lense?
No way you should rely on just the adhesive holding the lense in place.

Can you make more lenses for us?

You know those projectors that have the illuminated circle, used for day time running lights?

That would be cool.....

[fj johnnie]

 Very cool. It seems as though a lot of innovative people are on this forum. I like it!

[Paul1965]

Very interesting Paul....Some questions...

On your planned future dual setup, will they be side by side or vertical?

At speed, the wind pushing against the plexiglass lense can be substantial, does the housing support the lense?
No way you should rely on just the adhesive holding the lense in place.

Can you make more lenses for us?

You know those projectors that have the illuminated circle, used for day time running lights?

That would be cool.....

When I modify the housing I'll run the two projectors side by side. And so far I've hit 85 with the lens in place and there's been no issues. It's actually held in place with a plastic epoxy in three spots, the silicone around most of the rest of it. As far as projectors with halos in them, I put those in my Monte Carlo two years ago and love them. However to me they wouldn't make sense on a motorcycle because with the headlight on all the time, it would drown out the halo.

As far as making more lenses, I might consider it once I refine the process. The most difficult part was cutting the 18x24" molded piece of plexiglass down to size without damaging it.

[roverfj1200]

Looks like there is room for 2 in there.... Nice mod.....

[Paul1965]

Looks like there is room for 2 in there.... Nice mod.....

Yes, there's definitely room for two. The issue is that the headlight is really three pieces: the lens, the housing and the reflector. The reflector is what adjusts for up/down aiming so to be able to modify it to accept two projectors and still be able to aim it will be fun.

[Paul1965]

One thing to keep in mind, and really I don't know if it really matters, is that my FJ is an 84 and my headlight bolts to the fairing, not to the frame (I think 84-85 are like that). I can't imagine it would make a difference but I have no way of knowing if this project would work on other year FJ's.

[candieandy]

Looks Awesome. I'll take one with 2 HID Projectors in it(with electronic shutters) and a Daytime Running LED bar in it. that would be sweet.