996 Mk1 Headlight Cover Upgrade

[RNajarian]

I like the look of the Variel designed headlight covers for the 996 sold by our host.

https://forums.pelicanparts.com/porsche-996-997-991-forum/968687-new-pelican-parts-headlight-covers-99-01-996-mk1-02-04-996-mk2.html

I did some research comparing them to the fiberglass (knock offs) sold on eBay. Admittedly there is a price difference between the eBay fiberglass units and the Variel flexible polyurethane ones, but after close inspection of the photographs it is evident the flexible polyurethane units would fit and blend in to the vehicle much better.

I ordered the headlight covers at 8:30 am Thursday, got my 10% PCA discount, covers were delivered Friday at 4:40 pm.

I’ll share photos of the project as it progresses. . . hopefully my wife likes the upgrade once it is completed.


Trial fitting in a spare headlight unit


After first coat of primer (with a pair of bumperettes I’m also painting)


2000 996 Cab Turquoise Green Metallic (25D) before

[RNajarian]

9/19/2022

Four coats of primer on the covers. . . Next some light sanding then I’ll put on the color coat.

Question for anyone who has done this project. . .

Do you recommend using the double sided 3M tape or the silicone adhesive.

Thanks

[RNajarian]

Here is a photo of the headlight cover resting on the headlight after two coats of color.

I will let it dry 2 days, color sand and apply two more coats of paint.

— In case anyone is wondering . . . the frunk is open.

[fisher22]

That looks amazing! Very cool look.

[RNajarian]

Project Update:

I had some questions about the installation of these headlight covers. Our Moderator Dmitry set me up with a representative from Variel the manufacturer of the 996 Gen 1 headlight covers who was able to resolve my questions in less than a day. Here is the correspondence:

Question:
”A follow up question to your GEN 1 996 headlight cover.

I know removing the triangle headlight cover piece from the headlight assembly is required to properly fit the headlight cover.

Can the actual headlight washer remain (the unit that remains in the car when the headlight is removed) Or does that need to be taken out as well?

I’m putting the final coats on my covers and am curious if I will need to disassemble/remove/plug up the headlight washer system once the headlight comes out.

Thank You”

Answer from manufacturer
”Regarding your question, as long as you have popped out the washer and it's not keeping the covers from laying flat, then I don't see a reason why you would have to remove it entirely. I believe there is a fuse you can pull in the fuse box that would disable the headlight washers. That's probably the easiest way.”



I appreciate the prompt reply. I did some further research and found a thread on Rennlist that details how to completely remove the headlight washers. Apparently a very easy mod.

Thanks to dkraige who documented this procedure.
https://rennlist.com/forums/996-forum/1036783-litronic-headlight-washer-delete.html

”I think headlight washers are stupid, with the possible exception of a car that's going to get driven long-distance in high-salt winter conditions. Even then I think you can stop and wipe the lights off every couple hundred miles when you take a break for food or fuel. It's just not worth having them for the ugliness and potential leaks.

I decided to delete the headlight washers on my 2001 996. Here's what you need:

1) Left Side Non-Washer Lens Part Number: 99663104500
2) Right Side Non-Washer Lens Part Number: 99663104600
3) Plugs to terminate the washer fluid hoses in place of the washers, so washer fluid doesn't drool out. I used a small dowel of aluminum, about 3/8" in diameter, to clamp down on using the original hose clamps.

Steps to remove are as follows (I didn't take photos but this is pretty idiot-proof):

1) Remove the fuse for the headlight washer pump. This will prevent accidentally actuating the pump, meaning that your plugs only need to resist the head pressure, not pump pressure. Look up your fuse diagram since different years/configurations probably have it in a different location.
2) Remove the headlights using the tool in the toolkit or a 5mm socket.
3) Unbolt the headlight washers; each is held in place by a single nut.
4) Disconnect the hoses from the headlight washers.
5) Plug the hoses with the plug of your choice.
6) Secure the hoses with zip ties, etc. so they don't rattle around.
7) Carefully snap the lenses with holes out of your headlights.
8) Carefully snap your new non-hole lenses in place.
9) Reinstall headlights.
10) Enjoy!”






These still shots were taken from a couple of YouTube videos. They illustrate the headlight washer I will have to remove if they interfere with the headlight cover fit.







Should the cover fit with the washer nozzle still in place I will definitely have to pull the fuse or disconnect the pump to the headlight washer, since it is designed to lift up 2 inches during operation.


I will be adding some more color coats to my covers this week and begin polishing them up. Hopefully I will have some photos of my progress soon . . .

[RNajarian]

Almost ready to go . . . but. . .

I used the same lot of paint for the headlight covers that I used for my bumper cover update. . .

. . . but unfortunately I am not getting the exact match with the headlight covers that I got with the bumperettes. Oh and yes it is the same car. The bumperettes photo was taken in the garage with LED lighting and the headlight covers photo was taken outside with indirect sunlight.

It is close. . . but noticeable. I’m beginning to think I may need to take the covers to a professional. The covers have not been polished yet so MAYBE that’s what has to be done. Perhaps I’ll work on a small area to see if it makes a difference.

[fisher22]

It’s a great look. I do see the difference, but it could just be the finish difference, not color difference.

[RNajarian]

Thanks Fisher22,

I’ll polish them up and see if it makes any difference.

[RNajarian]

I’ve polished the clear coat pretty well. I have some more to do to eliminate what little “orange peal” is left.

It looks OK.

You can tell a slight color difference not concours quality but well you be the judge. . .

[fisher22]

From the angle of the photo, the panels look slightly less glossy than the bumper - which could affect the perception of the color. But you would have a better vantage point.

All in all it’s a very cool look.

[RNajarian]

Though the color on the headlight cover may be a little off, Fisher22 was right that there was a difference between the gloss of the bumper and the headlight cover which may explain the difference in appearance between the two.

So I polished the left cover even more and under incandescent and LED garage light got these results . . .

Polished Left headlight cover (on the right) with unpolished Right headlight cover (on the left)


In this light the color difference isn’t quite as noticeable




One thing for sure, a black or white car would be easier to color match.

[fisher22]

Originally Posted by RNajarian

One thing for sure, a black or white car would be easier to color match.

Maybe, but black & white have many variations as well. But even then, you wouldn’t have a cool, rare color that you have.

All in all I like it! Looks so much better than original clear polycarbonate actually.

[RNajarian]

I have extensively polished the left headlight cover to the point where it is “orange peal” free.

So I decided to do a trial fit of the left headlight cover, knowing the color is going to be off a little. . .

1) Remove headlight

2) Remove headlight washer triangle piece.

3) Remove the headlight washer. This is easy, remove gold nut, then remove washer assembly from plumbing. I cut the hose due to concerns pulling the hose off may damage the connector to the 23 year old headlight washer. I plugged the hose with a test tube stopper I had. Later I will pull the fuse to the headlight washers since they will no longer be needed.

4) Replace headlight.

5) I noticed there is a small glimmer or “flash” of the headlight when I laid the cover on the headlight. Easy fix. A small 5 inch strip of electrical tape over that area resolved the issue.

6) Place double sided 3M foam tape on the headlight, place cover, gently apply pressure.

That’s it. I’m not quite sure what to do with this color difference. I may wait to see how it looks in different light. Worst case scenario have a professional paint them.

The upgrade was VERY easy and I do like the 997 look much better.


Trial fit on bench




Gold nut holding headlight washer assembly in place.








Visible small strip of original Gen1 headlight


With black electrical tape in place

[RNajarian]

The 996 Mk1 headlight cover is one of the easiest upgrades to do. Once the covers are painted the process of installing them takes less than 10 minutes per headlight. Below are some photos of the right side headlight installation.

Despite using the correct paint code (25D Turquoise Metallic) the headlight covers are not a 100% match. Close but not close enough. I will likely have to take the car to a pro to get the perfect match.

I have yet to see the covers on the car in full sunlight, I’ll post photos as soon as I can.

[RNajarian]

Additional photos. The color is not quite right. Off to a pro we go. . .

[Tsunamiboy]

I don't get it? It's a 996!

[RNajarian]

Yes. Love the car, hate the headlights.

[doctorz1026]

I purchased the same set of headlight covers two years ago and ran into the same paint "matching" problem. If the paint does not match perfectly in ALL lighting conditions, it looks like a cheap garnish to your fried eggs. It's embarrassing! I also had a door panel to paint. So I spent about 3 months of trial and error before I discovered the secret to a perfect paint job.

First, I ordered color-matched paint from AutomotiveTouchup in a convenient spray can - it was close but did not look like the same color. Then I went to the Sherwin Williams Automotive Finishes store that supplies many paint shops in town. I got a paint that matched looking straight-on but was much darker when looking from the side. Then I asked the dealer what they use - they use a paint shop in town that uses Sherwin Williams. I went to a number of auto paint shops and learned that "color matching" involves "blending" the new paint into the old across a body panel. When done right, you don't notice the difference - unless you're looking for it.

Finally - UREKA! I found a small paint shop that really knows what they're talking about. Metallic paint (like most Porsche colors) has two characteristics called flip and flop. Flip is the color you see when looking straight-on, perpendicular, or 90 degrees to the surface. Flop is the color you see when looking obliquely, or about 30 degrees to the surface. So with thousands of choices for flip and thousands more for flop, it's quite impossible to mix a "matching" color from those hundred or so pigments that they select from to squirt into a neutral base. So what's a Porschephile to do?

You need to get paint from the same manufacturer that Porsche GMBH uses. And that manufacturer is the Glasurit division of BASF (glasurit.com). Porsche has been using (and still does) Glasurit paint for as far back as I could research - possibly to the 50's. It's the brand Porsche Classic uses. When you get paint mixed with Glasuit pigments, you get the exact same color as Porsche used when manufacturing your car - both flip and flop. I painted a door panel and there was no "blending" required. The door panel and the fender next to it look identical in color from all angles.

So where to get Glasurit paint? I was lucky to find a local distributor - English Color and Supply (englishcolor.com) named for founder Bob English. They have branches in 12 states and may provide mail order. At my request they pre-thinned the paint for the local conditions so I could load-and-spray. BTW, they said there is no need to get Glasurit clear coat. Any high quality (but less expensive) clear coat will do.

Now that you have the paint, what do you do? The easiest thing would be to take it to your local paint shop and have them do the job. But I did it myself using a Harbor Freight spray gun which worked quite well. I was fortunate that English Color knew a guy who paints restoration Porsches who gave me some tips. I used one light color coat, waited 5 minutes, then one finish coat. I then mixed the 2-part clear coat, applied one light coat, waited 15 minutes, then applied the finish coat fairly thick. It can be polished after 12 hours. One very important tip that the expert gave me is NOT to apply a "dust coat". Many web sites say that metallic paints look much better when you apply a light dusting of paint as the final coat. This is not recommended for Glasurit paint.

So now that you know "the secret", go forth and conquer! And enjoy having your 996 mistaken for a 997 without people saying "What did you put on top of the headlights?"

[RNajarian]

Thanks Pal. . . great advice !

[WPOZZZ]

We need pics of doc's car!