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CEO, Pelican Parts Inc.
 
Wayne at Pelican Parts's Avatar
959 Project: Headlamp film...

I realized recently that the cost of replacing one of the glass headlamp lenses on the 959 could be in the thousands of dollars range, so I decided that it was wise to spend some $$$ on some headlamp film to protect them. I measured the size of the headlamps, and then I ordered a custom-sized sheet from Xpel, that would cover the size of the headlamps. They custom-cut the standard 3M film that is an industry-standard for this stuff:



Next, I removed the headlamp ring and used it as a pattern to get a rough idea of where to cut:



Here's my pattern drawn on the film:



Next I cut out the pattern with a sharp knife. The film is pretty tough and a bit thick, so it requires some effort - use caution, and make sure you use a fresh, sharp blade.



Here's the finished cutout:



And here it is laid against the headlamp ring:



Front shot of car with the headlamp ring removed:



Obligatory far away shot:

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Wayne R. Dempsey, Founder, Pelican Parts Inc., and Author of:
101 Projects for Your BMW 3-Series 101 Projects for Your Porsche 911 How to Rebuild & Modify Porsche 911 Engines 101 Projects for Your Porsche Boxster & Cayman 101 Projects for Your Porsche 996 / 997
Coming in 2014:
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Old 11-10-2007, 12:55 AM
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CEO, Pelican Parts Inc.
 
Wayne at Pelican Parts's Avatar
I laid my cut film out against the lamp. It was close, but not perfect:



Another shot:



I then peeled back the film and applied it with the rubber spreading thingy they include with your order. I got one or two bubbles in there, so I had to peel it back again. They say this shouldn't affect it too much - the film cures over 48 hrs or so.



The outer ring wouldn't fit back on because there was significant overhang on the film, so I got my blade out and cut away the excess. It's not a perfect trace, but you can't see any issues, unless you get your face down about 4 inches from the headlamp.



Here's the finished product with the headlamp ring back on and the headlamp turned on:



I thought the film might dull the headlamp's light, but it works just fine. Here's a shot of the left and right lamps, with the film applied to the headlamp on the left of the picture only (passenger side).



Obligatory cool car shot in our warehouse:

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Wayne R. Dempsey, Founder, Pelican Parts Inc., and Author of:
101 Projects for Your BMW 3-Series 101 Projects for Your Porsche 911 How to Rebuild & Modify Porsche 911 Engines 101 Projects for Your Porsche Boxster & Cayman 101 Projects for Your Porsche 996 / 997
Coming in 2014:
101 Projects for Your MINI Cooper
Old 11-10-2007, 12:57 AM
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Wayne, I guess it's the rarity of the car, but I just love to follow these threads. Keep them coming.

I love to see you take apart the 4wd system
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Old 11-12-2007, 08:24 AM
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Wayne, good idea. I know how tough the film is from using it on airplanes.

Any idea on what a bulk buy would cost to get the film pre cut to fit H-4's? I would like to stop my lenses from being pitted.
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Old 11-12-2007, 08:37 AM
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You are a brave man to install these without floating them on with a mixture of 10% alcohol and distilled water. When you use this mixture you won't get fingerprints on the edges and centering the film is 100X easier. No need to worry about cutting a kit for H4/H1 lens. We have them for sale on our ebay listing # 290180723343 In stock and ready to ship.
Made from 30mil thick optically clear urethane material, not the thin material used in paint protection kits or also called helicopter tape. Installation instructions included.
http://cgi.ebay.com/ebaymotors/Porsche-911-912-Bosch-H1-H4-Headlight-Protection-T-E-S_W0QQitemZ290180723343QQihZ019QQcategoryZ34207QQs sPageNameZWDVWQQrdZ1QQcmdZViewItem
Regards,
Charles
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Last edited by Bench-Racing; 11-12-2007 at 10:09 AM..
Old 11-12-2007, 08:45 AM
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Wayne at Pelican Parts's Avatar
Quote:
Originally Posted by PorschePilot View Post
Wayne, good idea. I know how tough the film is from using it on airplanes.

Any idea on what a bulk buy would cost to get the film pre cut to fit H-4's? I would like to stop my lenses from being pitted.
I paid less than $20 for a size about 11x17 which will cover both lamps. Precut is nice, but after doing this, I would prefer to cut them to size once they are on the car. It allows for more flexibility when placing it on the lamp...

-Wayne
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Wayne R. Dempsey, Founder, Pelican Parts Inc., and Author of:
101 Projects for Your BMW 3-Series 101 Projects for Your Porsche 911 How to Rebuild & Modify Porsche 911 Engines 101 Projects for Your Porsche Boxster & Cayman 101 Projects for Your Porsche 996 / 997
Coming in 2014:
101 Projects for Your MINI Cooper
Old 11-12-2007, 10:30 AM
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I think some custom head light grills would look kinda cool on there.
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Old 11-12-2007, 10:31 AM
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Damm that thing is awesome
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Old 11-12-2007, 10:44 AM
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I'm going to refer to this thread when putting film on my 959 headlights. Fortunately, the 916 headlights retract.
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Old 11-12-2007, 12:42 PM
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Does Pelican sell this bulk sheet ? I need to cover some megga $$ Euro lamps on my Vanagon Parts hauler...

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Old 11-12-2007, 03:47 PM
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Very cool. Can you get the yellow "fog" type film for that funky rally sort of look?
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Old 11-12-2007, 03:48 PM
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I have over 30k x-country + 10k local miles on the same 3M film that i bought from pelican a few years ago.

Before that I tried the clear thin plastic bubbe type. It extends 2" off the lens. It has better optics but either gets dented by road crap or someone smacks it.

The 3M can take a beating and keep on ticking. Optics is still great after years of abuse at a cost of 10% light power. I couldn't tell the 10% difference with high watt bulbs. Every once in awhile a new little bubble will appear or the edge may have to be patted down.. maybe 2x/yr. On brand new lens' you can keep new optics using this.


good stuff
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Old 11-12-2007, 04:04 PM
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I used the same 30mil thick 3M product from Xpel.com in 2006 at LeMans to protect the lower apex lights on this Saleen. I used the 8mil clear on the upper headlight covers. The car did complete 24 hours and the protection film worked very well.
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Old 11-12-2007, 04:50 PM
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Quote:
Originally Posted by Porsche-O-Phile View Post
Very cool. Can you get the yellow "fog" type film for that funky rally sort of look?
you can get yellow film at www.lamin-x.com
you can barely see it on my car behind the mini.

Old 11-12-2007, 05:18 PM
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re Vanagon Parts hauler - throw those dang things away & get the good round lights and the South African grill to match them. YOu'll be impressed with the light then!
Old 11-12-2007, 07:34 PM
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