yay for fiberglass

[tjts1]

This is the first time I've ever set hands in fiberglass so its kind of a rough work in progress. With any luck I should have the highbeams and paint and ready for Davis. The covers are simple molds over the glass ecode lenses. Sorry about the picture quality. The camera is permanently set on out of focus.
http://img.photobucket.com/albums/v242/tjts2/volvo/da16eaa1.jpg

http://img.photobucket.com/albums/v242/tjts2/volvo/b982b275.jpg

http://img.photobucket.com/albums/v242/tjts2/volvo/40cd0fbd.jpg

[Poik]

Very good job... I was thinking of doing something similar for the 242 in the size of the single rounds, with bigger projectors.

[tjts1]

http://img.photobucket.com/albums/v242/tjts2/volvo/466baa7e.jpg

http://img.photobucket.com/albums/v242/tjts2/volvo/df730c79.jpg

[badvlvo]

This BETTER be done by Davis! That's some great engineering.

Nice job.

[fryea]

me loves fiberglass

keep us updated on these, lookin hawt so far

[klr142]

That's sweet man!!! Can't wait to see the finished product. Are you going to incorporate any other lights in there? Or just the one projector?(well, actually, I assume you are as you say you'll have the high beams ready, etc, so those are the low beams?) Are the high beams going to be the same size?

[tjts1]

That's sweet man!!! Can't wait to see the finished product. Are you going to incorporate any other lights in there? Or just the one projector?(well, actually, I assume you are as you say you'll have the high beams ready, etc, so those are the low beams?) Are the high beams going to be the same size?
I'll use the 90mm projectors for low beam (pictured) and Hella 500 driving lights with slightly modified beam pattern for highbeam. The highbeamd is about twice as lage as the low beam and it will stick out some. Nobody seems to like it. Makes the car look a cross eyed. But the lage round reflector is super efficient and with the 100W bulbs it can turn night into day like else.
This is how it looked before
http://img.photobucket.com/albums/v242/tjts2/volvo/8ecdf7cc.jpg
In the new version I moved a couple if inches further out toward the corners in or der to avoid the cross eye look.
http://img.photobucket.com/albums/v242/tjts2/Picture183.jpg
The problem with this setup was the ecode lense was blurring out the low beam pattern. The projectors make a very nice Z beam on their own.

[acbarnett]

reverse the placement of the lenses, like with the highbeams on the outside and the low projectors on the inside...

[Chris_R]

To clean up the beam patterns you'll want to deflute the lenses.

Search over at VS, exexpat did a great writeup on defluting lenses.

[tjts1]

To clean up the beam patterns you'll want to deflute the lenses.

Search over at VS, exexpat did a great writeup on defluting lenses.
Yeah that was a original plan about a year ago but i decided against it. Too much work with compromised beam. Besides the projector looks awesome on its own.
reverse the placement of the lenses, like with the highbeams on the outside and the low projectors on the inside...
The length of the projector would interfere with some bodywork behind the headlight housing and the intake on the driver side. It would also make it really hard to change low beam bulbs.

[acbarnett]

ever consider a projector with a wider reflector or halo around it like BMW's, audi's and the new VW's have?

[isaac]

It looks like you slaughtered an octopus to get those headlights.

[tjts1]

ever consider a projector with a wider reflector or halo around it like BMW's, audi's and the new VW's have?
I don't really like the BMW halo thing. It would look a little too much like I'm trying. I picked the 90mm because its the highest quality halogen projector I could find a year ago at the lowest price. This ruled out most of the H7 alternatives although there is a 120mm version.
It looks like you slaughtered an octopus to get those headlights.
How did you know?

I made a little more progress on the highbeam.
http://img.photobucket.com/albums/v242/tjts2/volvo/9327f2ec.jpg

http://img.photobucket.com/albums/v242/tjts2/volvo/c882c6aa.jpg

http://img.photobucket.com/albums/v242/tjts2/volvo/1fbf41c3.jpg
Whats the best kind of paint to use on fiberglass? Do I need to scuff the surface or primer? I want to paint it flat black to match the grill. Come to think of it, I should probably repaint the grill while i'm at it.

[lizadactyl]

the shaggin wagon still looks CROSS EYED... I'm not sure how I feel about that right now.

[SteveMD]

It looks like you slaughtered an octopus to get those headlights.

:rofl: 2 octopi?

[blarf]

The highbeamd is about twice as lage as the low beam and it will stick out some. Nobody seems to like it. Makes the car look a cross eyed. But the lage round reflector is super efficient and with the 100W bulbs it can turn night into day like else.

Get a 90mm high beam lamp. It'll look better, and still light up the road. The high beams you have now throw out a pretty narrow beam anyhow.

[tjts1]

Get a 90mm high beam lamp. It'll look better, and still light up the road. The high beams you have now throw out a pretty narrow beam anyhow.
I fixed the narrow beam issue. Simply moved the bulb in the housing back about 2mm which created a much wider beam. It rocked all the way back Limantour

[Homer1]

Ewww

[CaptainWhoosh]

I like the projector look, but not the high beam, but hey if you like it then rock it all night long, good work!

[tjts1]

I got no love for haters.
http://img.photobucket.com/albums/v242/tjts2/a5978199.jpg

http://img.photobucket.com/albums/v242/tjts2/42aeb4bc.jpg

http://img.photobucket.com/albums/v242/tjts2/cec28411.jpg

[DoubleV]

Very unique looking... I must admit the light output looks incredible! Have you considered painting the fiberglass section white to match the cars paint? I think that could look interesting.

[Delfosse]

now do it to the corners some how.. youll be set!

[PRVersion]

i give it a 6 on the gary busey scale....but that output is hawt...

[some guy]

I think it looks more startled than cross eyed personaly. Kinda like: :omg:

Still, nicely done.