Jenni / Legomans SRT-4 - heatshield, paint and hood lifters!

[Jenni]

How it all started in april 2008:
VW Passat bi-xenon lenses











but very quick i found out that it is impossible to mount the lens to the reflector. that was the point where i stuck with the project till aww sheet came with his "mounting plate" idea. And so it was time to continue!











the blue vinyl should give me an idea how it will look in the end and was a try if it would work w/o vacuforming. But it didn't....

so i started building a vacuúm table.
also big thanks to aww sheet!!!!
and today:

I finally finished my vacuum table.
Awesome how great it works.
With a simple 50$-vacuum cleaner.
Just need to vacuform the 2nd shroud and to piant it black!
Thank you guys for all the ideas - without you the project would still stuck like the last 1 1/2 years!













the shrouds. wasn't easy to find a way that theyboth look the same




and now the angel eyes
as you can see they are way too big!


so lets heat up the oven and bend acrylic and here is the first


and learn something new every day: if you don't pay attention and the oven is too hot - the acrylic starts to boil and the bubbles are really ugly and not really helpfull. dammit!


one more thing to do: modify the racoon thing


reflector painted (i don't wanna have a silver spot somewhere blinking)


and voila there it is, the finally painted shroud


and step by step it comes all together


and somehow like that it will look with the angel eyes


first angle eye finished and it looks absolutely great. light output, shape, just everything is perfect like i planned to have it.





But then it came.
Testfitting the headlight lense - and it fits not anymore.
dammit!
The VW lense is soooo huge that it barely fits into the headlight without touching the lense allthough they still look out at the backside of the headlight more than an inch!!!
So there was not enough room for the angle eyes anymore.



whatever - the headlights will also look nice without them and so my inner conflict was solved by the outer circumstances.
maybe in my next retrofit project...

installed the headlights today.
testrun before i finish them.

the before (the modern projectors with H1 hid kit):
i have no idea where the shadows come from








installed them (with free-in-the-air-wiring and w/o lense and shroud and such....):


you like it?




still needs height adjustment...


i like it. a very nice light output w/o any shadows.

[Passt]

Looks awesome!

[Alex Kurdian]

Mate 10/10 for effort looks great...I admire you all you guys heaps...you take apart all these bits and pieces and re design them...

maybe you all should all work for the car companies and design awesome cars from scratch !

[Ntyvirus1]

why don't you take the lenses from the MPX lights?

[Jenni]

because
1. they are shit (you see the difference in the light output???)
2. i cannot resell the MPx w/o lenses
3. i bought the Passat lenses in March 2008, the MPx 1.5 years later
4. i don't wanna drive around w/o lenses in my headlights while i work on the hids...

[measy27]

sick

[LilSparkPlug]

Very nice work Carsten

[dtjackten]

WOW!!!! those look great, and really good write up...

[Jenni]

Problems, problems, problems....
The front is finished now but the rear side?
The long lense sticks out of the housing and i would prefer to cover it somehow to lock the dirt and water out. But also i wanna have the chance to reach the bulb.






So hmmm - i need a cover with a removable cover.



TUPPERWARE!!!




And there it is, still very raw:



The good thing is:
Enough spare room in the box that the lense can move for height adjustment.


My wife the same time:





Tomorrow i will test if the headlight still fits fine into the car.


I know it looks very strange at the moment but that is just the viewing angle...
It's not as big as it looks like!
(And really - no one will see it once it is in the car...)

[JeffM]

Hahahaha! I like the ingenious design, Carsten! Tupperware to the rescue!

Are those D1S bulbs?

[Jenni]

yes, D1S!

[Tam]

So this is your first retrofit, right?

Not bad at all. But it's not comparable to aww sheet's work. lol

[lilnicko11]

nice bro nice.

[sidepipe87]

looks good. too bad that ballast is attached directly on the back. I remember someone else cut a 3" diameter piece of PVC pipe and it fit in that groove on the back, then covered it with a plastic or rubber cap to replace the bulb.

EDIT: It was Wiggy

[sxxxt]

Awsome J.o.b man

[Jenni]

Another project that i had to finish today:
Changing the lighting in the stock radio and made a how-to out of it!


the radio


remove the 4 screws (TORX)


remove the volume, balance and treble knobs


flip up the front panel


remove the connectors


remove the screws


don't loose one of the inner parts


pay attention the polarisation!!!


if you wanna have red light you can stop here and just remove the blue caps and install red rubber caps therefor!!


and thats it - bulbs removed, LEDs in. you can see my soldering needle. don't try to make that with a big fat soldering gun


install a 480 Ohm resistor here


isolate it!


and then you can reassemble everything!

and there it is. open:


and closed

[bstc00]

The radio came out nice. what leds did you use.

[NeonOn19s]

very nice!!!!!!!!

[Jenni]

thank you! 3mm bright blue

[measy27]

Love the radio leds

[neonslg09]

The mode button is serious business!! haha

[Jenni]

look what was in the mail today fresh from Hongkong:



so first i removed the trunk lock and drilled the hole open to 31mm


trunk lid alarm switch - cut and conected both wires...


and thats it, 4 hours later after a lot of wiring (and hiding wires...)!




it has a wide angle and infrared lights. so the viewing even in the dark is super!!!

here i bought it:
http://cgi.ebay.de/ws/eBayISAPI.dll?Vie ... 0392418565

[dtjackten]

nice job with the lights in the stock radio, a very nice touch!!

[Themaggots]

Oh wow. Very nice idea on the back-up camera. My trunk lock isn't working so I might do this too.

[Danteneon]

I like that camera you used. Very cool! I may have to look into doing this on the Caliber.

[Tam]

I like that idea! Great work on the radio and the camera. Very nice and original mods.

[LilSparkPlug]

I still have to install mine, I've had it over a year.

[Jenni]

i could do that for you. just come over here and bring beer and burgers.

[LilSparkPlug]

LOL! That would take a while!

[Jenni]

dammit i finally finished the project.
every day another obstacle!!!!


how to open headlights, the brute force method. don't do this at home kids!


okay, the tupperware thing was a dead end. it was not flexible enough and somehow to big. so i found something else. axle boot!
easy to install, flexible and a hole for the wiring (hole is closed with zip tie now)


the closed headlight. dammit the lense fits barely over the projector!!


VERY IMPORTANT!
a diode for the highbeam.
you know: when you switch to high beam the low beam turns off. Okay with the 9007 bulb with 2 filaments but not good with HID bulbs.
So the diode makes 2 things: it sends the high beam signal also to the relay that the HID stays on - and it blocks the low beam signal.
Current can only flow from high beam to the relay - but not the other direction.
Low beam signal = HID turns on
High beam signal = the magnet flips the deflector for full light output and the relay turns also the HID on.
Without the diode i would have a flipping deflector - but the HID would turn of in the same moment....
Oh and also: If the headlights are off and i pull the multiswitch (headlamp flasher) -- the current flips the deflector and goes through the diode to the relay and tadaaaa headlamp flashes!!!
(i just wonder that i have never read that before here in the forums...)
Hmmm, i hope you can understand that...


final test fit. huuu i have 4 headlights...


low beam, high beam...




finally installed!!!!!!