Projector Headlights for less than $100????? HID for less than $400????

quaz · quaz's Garage

OK after looking at several pictures of the Singer 911 I can't take it anymore. I want updated headlights on my car. Now lets not go into the fact that my car barely runs and I have really only driven it around the block a few times in the last 3 years, but I am making progress on that front. My ITBs and Megasquirt are coming along nicely and I am working on tuning that in. However that is not the point of this discussion. To motivate myself to keep working on tuning I need some little project I can finish and this seems to be it.

What are the options for projector headlights or HIDs? Well the Singer has custom HID headlight made out of unobtanium, you can modify the fender to accept mini headlights, or make something yourself. I was looking for some bolt together solution for less than the cost of a used 2001 GTI. This might be it..........

After looking around endlessly I decided that the original 1965 headlights with the sealed 7" round headlight would make the perfect headlight to start with. The sealed 7" headlight could be replaced with either a cheap projector or a real HID which are both readily available. Real HID 7" round assemblies can be had for around $3-400.

Since I have hemorrhaged enough money into my car for the summer I took the cheaper route for the proof of concept. The original part number is 901.631.101.31 which you will need 2 of. However that part is NLA and if you find it NOS it is expensive. 1951 VW Beetle Headlight Assembly 111 941 037 C That is available all over the place and very cheap. I ordered 2 of those. Then from ebay I got 2x7" round H4 projector lights for $30 shipped to my door. Looks like this:

Here is my stock H4 next to the new assembly.

Cheap projector light off ebay.

At this point you have all the stuff, but need to put it together. The bug headlights will not bolt in, but if you have H4 or H5 headlight you can use your ring from them to mount the bucket. Flip the new light over and remove all the spring clips to separate the bucket from the light. Do the same to your H4 assembly. You will be putting the new assembly and lens in your old H4 chrome ring. (all to save several hundred dollars ;-)

After all assemblies are apart you can just swap the buckets over assemble and put in the car. I took it one step further and painted the buckets black to give a more updated look.

At this point I assembled one side and installed it to compare with the H4 and decide if I like it. I think I do and will probably assemble the other side tomorrow. Here is how it turned out. I think I have less than $100 into this project.

quaz · quaz's Garage

Bob Kontak · Bob Kontak's Garage

Damn, I can hardly tell the difference. Not.

Nice post.

RWebb · RWebb's Garage

looking at the color temperature difference in the lights won't tell you how well it [1] puts light onto the road, and [2] avoids blinding oncoming drivers, some of whom may run into your car if they are blinded

ratpiper71T · 10-01-2010, 03:13 PM

Pretty cool and creative. I'll be the nerd and ask though... What's the pattern look like on the wall the lights are cast on? And can you aim or is it at least fixed in the right direction? Beautiful longhood BTW..

quaz · quaz's Garage

When it gets dark tonight I am going to pull it into the driveway and see the spread/pattern difference on the garage door. If I don't like the pattern I can always swap out the 7" projectors with a different model. I just wanted to see if this conversion would work and what it would look like. Functionality is next up.

Why would I ever worry about other drivers though?

ratpiper71T · 10-01-2010, 03:51 PM

Quote:

When it gets dark tonight I am going to pull it into the driveway and see the spread/pattern difference on the garage door. If I don't like the pattern I can always swap out the 7" projectors with a different model. I just wanted to see if this conversion would work and what it would look like. Functionality is next up.

Why would I ever worry about other drivers though?

Hah! Well I guess, selfishly, I was thinking about whether or not you'd be able to to see on a not so well lit road at night! Driving with a cross eyed light kinda sucks. I bet though the whiter light probably lights up the road better regardless of whether or not you can aim it right.

Jonny042 · Jonny042's Garage

Very nice, very creative, and very good post.

They look great, but I think the silver would look even better than the "updated" black. Probably more subtle. Which is even cooler in my opinion.

But either way good job and thanks for posting.

Craig_D · Craig_D's Garage

Man, I like it!! I hope the pattern and brightness is exactly what you want and can't wait to hear how it turned out.

village idiot · village idiot's Garage

Nice, I just got done cleaning my H5's on my Carrera and though they're better, it still leaves something to be desired. This may be the way to go

MIK911 · 10-01-2010, 10:46 PM

Nice original thinking.
Anxious to see the light pattern.
Keep us posted

sobamaflyer · sobamaflyer's Garage

I like it!.....But I was thinking the same about the silver buckets, the black takes something away for me.

I like the idea of swapping the bucket to retain the HID/Beetle Lamp, any reason we can't keep the H4 Lens? Will it scatter the light and make things worse?

quaz · quaz's Garage

I managed to get the other side in last night, but just as I pulled it out of the garage and got these pics it started to rain. GRRRRRRRrrrrrr!!!!!!! If I have time tonight I will try to get some pics of the pattern on the garage. BTW the buckets can be aimed like the H4 assemblies.

To me the look is fitting with the style of my car. Hot rod with a touch of classic. However if you left the buckets silver or send them out for chrome it could give it an entirely different appearance more fitting of an early 911.

RWebb · RWebb's Garage

nice garage - more pics?

hawaiipcar · 10-02-2010, 10:16 AM

Thanks for posting this been wanting to do this type of conversion.

john walker's workshop · 10-02-2010, 11:17 AM

interesting that the bug chrome rings you found are flat on the top area, to match the 911 fender curve, like the early 911/912 euro lights. all the bug rings i've seen are rounded and don't look right on a 911. what did you do about the lower mounting tab on the vw unit? cut it off and drill and dimple a screw hole in the rim?

wwest · wwest's Garage

You mean...

Like this...??

1978 Targa, projector beam , 4300K HID, Bi-Xenon (solenoid actuated shading aperture drops aways for high beam mode).

Less than $250 overall.

quaz · quaz's Garage

Quote:

Originally Posted by john walker's workshop

interesting that the bug chrome rings you found are flat on the top area, to match the 911 fender curve, like the early 911/912 euro lights. all the bug rings i've seen are rounded and don't look right on a 911. what did you do about the lower mounting tab on the vw unit? cut it off and drill and dimple a screw hole in the rim?

I used the H4 ring from the 911. The bug ring definately won't fit. The assemble for the Bug is just more readily available then the 911 one.

mickey356 · 10-02-2010, 01:36 PM

WoW! What a cool post!

quaz,
I can't wait to hear the rest of this.

wwest,
What is that light from? Is that something that can be put into quazs project as well, or is it a completely different light fixture? It's very cool looking but it doesn't look like it plugs right in, did you have to do some fancy wiring work?

rothaus · 10-02-2010, 05:01 PM

Are you still have H4 in the projector or HID ?

And how does the low - high beam switch work ?

I did a conversion last year and used BMW e46 bi-xenon in the same housings you used, however, I agree the original H4 rings look much better, as the rounded once.

Here is more from that post last year, scroll down.
HID Xenon for 911 - Initial pics

Nice job BTW.

Cheers