I've been doing a lot of brainstorming on how to make an HID or better yet, a projector headlight work the best in our FJ's. Since the OE lens distorts the projectors light and scatters an HID's light, I think the solution is to make a custom, clear lens. So I did some research and ran across some DIY videos on YouTube about making your own vacuum forming table for molding objects out of plastic. I read a lot of car forums where users made their own car headlight lenses with great results. However, I don't feel like buying the materials to build my own table, so I jumped online and found a local company that does custom molding right here in Palatine IL. I sent him a pic of the headlight and in fact, just left there after physically showing him what I want. The initial estimate is probably around $40, and would be less if there's a larger number to be made. So my question is, who else is interested? I can probably supply a donor lens for the 84-85 FJ's, but I think the headlight is different for 86 and up so I'd need a donor lens from someone else. What do you guys think?
The DDM HID works perfect with my OEM reflector on both my FJ and Toyota Tacoma. Since the DDM system uses the OEM plug to get signal for on/off and high beam, if the bulb or system fails, I can switch back to a standard bulb by pulling horn out to access the bulb. Almost tool-less to switch. Once I change the horn and put it there the charcoal canisters are then it will be 100% tool-less to swap back.
Quote from: FJmonkey on September 20, 2013, 04:04:25 PM
The DDM HID works perfect with my OEM reflector on both my FJ and Toyota Tacoma. Since the DDM system uses the OEM plug to get signal for on/off and high beam, if the bulb or system fails, I can switch back to a standard bulb by pulling horn out to access the bulb. Almost tool-less to switch. Once I change the horn and put it there the charcoal canisters are then it will be 100% tool-less to swap back.
...But difficult to switch back at night when entering a twisty or two at speed. Please research for absolute, g`teed best quality HID...and don`t ask why I don`t trust`m!...I copped flak for saying they were rubbish...I still think so! :flag_of_truce:
I think it was Alf that put a lot of work into this subject...then gave up.
I would ensure you have additional spot lights first ...the main priority. imho
Quote from: The General on September 20, 2013, 04:22:23 PM
...But difficult to switch back at night when entering a twisty or two at speed. Please research for absolute, g`teed best quality HID...and don`t ask why I don`t trust`m!...I copped flak for saying they were rubbish...I still think so! :flag_of_truce:
I think it was Alf that put a lot of work into this subject...then gave up.
I would ensure you have additional spot lights first ...the main priority. imho
I will look for reviews and rants on the DDM HIDs, my personal experience with DDM has been very good. I have heard bad reviews on other HID systems, perhaps others beg to differ. Thanks for the heads up.
Id be interested in a custom lens , and the headlights are the same up to 91 , I think that's where they went pair shaped :biggrin:
Quote from: fj11.5 on September 20, 2013, 05:22:45 PM
Id be interested in a custom lens , and the headlights are the same up to 91 , I think that's where they went pair shaped :biggrin:
Excellent, thanks for the info fj11.5
My experience with DDM has been mixed. I had an inordinate amount of trouble with the DDM kit installed in my Dad's Camry. I finally removed the kit prior to sale of the car, otherwise I'd be repairing it for the new owners as well.
Another problem is they apparently don't stock anything in the US any longer. It's all drop-shipped from the Chi-coms now. No place an order, drop by to get it in will-call. Warranty exchanges: 2-3 weeks. They don't have 'great deals', but their prices are OK. You can do just as well buying off flea-bay, IMHO.
Quote from: Paul1965 on September 20, 2013, 05:54:30 PM
Quote from: fj11.5 on September 20, 2013, 05:22:45 PM
Id be interested in a custom lens , and the headlights are the same up to 91 , I think that's where they went pair shaped :biggrin:
Excellent, thanks for the info fj11.5
That's up to (but not including) '91. The '91-'93 use the same headlight assembly...and the '84-'89 use a different headlight assembly.
Cap'n Ron. . .
Thanks cap, was just a rough guess,
Rod
Quote from: FJmonkey on September 20, 2013, 04:04:25 PM
The DDM HID works perfect with my OEM reflector on both my FJ and Toyota Tacoma. Since the DDM system uses the OEM plug to get signal for on/off and high beam, if the bulb or system fails, I can switch back to a standard bulb by pulling horn out to access the bulb. Almost tool-less to switch. Once I change the horn and put it there the charcoal canisters are then it will be 100% tool-less to swap back.
Works perfect, doesn't break; or works perfect, projects a usable beam pattern through the original FJ lens? Because I really like seeing a noticeable cutoff pattern or I don't spend money on aftermarket headlights.
Thanks ya wee monkey :)
I really want to put a projector in mine instead of just an HID kit. I converted my Monte Carlo over to projector headlights and absolutely love them, I can't help but think it will be one of the best upgrades to do on my FJ too. This is the kit I have in mind: http://www.ebay.com/itm/151100356195?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649 (http://www.ebay.com/itm/151100356195?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649)
I don't care about angel and devil eyes. What I like is that it's bi-xenon, 55 watts and comes with the better AC ballast. And at 2.5 inches is should fill in the headlight housing quite nicely.
Awesome kit mate, , a few bikes have these as oem , they work great :good2:, much better than hid kits in a standard headlight ,
This may be of interest to those recently discussing headlight upgrades. This guy seems to have the problem covered.
This as an FJ1100 (Toyota MR2) for sale here at the moment.
(http://farm8.staticflickr.com/7430/9893683543_89a616f0a1_b.jpg)
Although no one's asked. I know you want to see the rest of that "FJ1100"
Here's the link to the ad with all the photos:
http://www.gumtree.com.au/s-view-details.html?adId=1023367661 (http://www.gumtree.com.au/s-view-details.html?adId=1023367661)
Noel
,Someone had plenty of money :biggrin:, that's a lot of effort just to get decent headlights
Well, I finally got the finale estimate for having a new lens molded. And while they would be only $45 each, setup and pattern costs completely blow the price out of proportion. At a total of $750 for having 6 lenses made I can't help but think they priced it so high so they could get out of doing such a little job. So it's back to making my own forming table and see what happens.
That's only slightly higher than the quote I got for having a bellypan and mould made,,, good luck making your own, id still be interested if you make extras
Rod
Quote from: fj11.5 on September 24, 2013, 04:16:42 PM
That's only slightly higher than the quote I got for having a bellypan and mould made,,, good luck making your own, id still be interested if you make extras
Rod
I really think it's a matter of them not understanding what I'm asking for. I exchanged a few more emails with them after getting the quote, and they're thinking they needed to vent the glass and do some other special setup work to make the mold. My donor headlight should be here Thursday, so I'm popping the lens off and heading back Friday to show them what it looks like outside the bike.
Fingers crossed once they see what your actually after the price will drop, I wouldn't of thought vents would be needed
The donor headlight arrived today and the lens has already been removed. I'll stop by the molder tomorrow afternoon and see what they say.
Excellent, thanks for the update mate
Cant wait to hear the result!
This might be the most tempting mod for me this winter :good2:
Just wondering if there has been progress on the projector / OEM lens fabrication project.
A friend put 2 HID projectors in a Suzuki TL1000 behind a replacement "lens" for the TL1000 he found online that has no lens facets or lines, ie plain high impact plastic like a helmet visor so the projector can do its thing without scattering.
I will tell you he spent a lot of trial cutting and fitting to bike plastic to mount the projectors in the frame and also sealing the replacement lens into the body work. But the results are scary bright and distinctive.
Quote from: Paul1965 on September 26, 2013, 07:07:12 PM
The donor headlight arrived today and the lens has already been removed. I'll stop by the molder tomorrow afternoon and see what they say.
How did you remove the lens ? Heat gun?
George
Quote from: movenon on April 13, 2014, 05:49:39 PM
Quote from: Paul1965 on September 26, 2013, 07:07:12 PM
The donor headlight arrived today and the lens has already been removed. I'll stop by the molder tomorrow afternoon and see what they say.
How did you remove the lens ? Heat gun?
George
Hi George. Yes, just a few minutes with a heat gun and the adhesive was soft enough to pop the lens off. I've got a vacuum table made, just haven't had the time to build the frame necessary to hold the plastic.
So I guess you are going to end up with a clear lens as are on the newer cars and adapt a projector bulb on to the back side ? Sounds interesting for sure.
George
Found this on the internet,
May be usefull
http://www.theretrofitsource.com/closeouts.html (http://www.theretrofitsource.com/closeouts.html)
Alain
Quote from: movenon on April 14, 2014, 03:11:40 PM
So I guess you are going to end up with a clear lens as are on the newer cars and adapt a projector bulb on to the back side ? Sounds interesting for sure.
George
+1 on this. Forgive me if I'm covering old ground here, but this seems important for this project.
I am sure you know that all of the focusing of the beam takes place in the fluted lens on a stock FJ headlight, while the newer "projector" lamps all use the reflector to focus the light. It has to happen somewhere, or else it's gonna look like a 40 incandescent bulb in your table lamp, except brighter &
LESS focused.
Quote from: movenon on April 14, 2014, 03:11:40 PM
So I guess you are going to end up with a clear lens as are on the newer cars and adapt a projector bulb on to the back side ? Sounds interesting for sure.
George
George that's exactly correct. In fact, I'm almost toying with cutting the back completely off the old housing itself (where the bulb mounts) and make a new one that will allow the installation of 2 projectors instead of just one. I've been watching a dual kit on eBay for a while now and I'm pretty confident they'll both fit. It's just with all the other stuff I've got going on I haven't had the time to get around to making a frame and testing out my table and the whole vacuum forming process. In fact I might just say the heck with it and try fitting some high impact plastic directly to the fairing instead, but I don't think it will work as well.
Keep up the good work. It all has to start somewhere. Modifications are that way. Working on a couple myself. Sometimes its just takes a while to figure things out. Persistence Paul.. :drinks: Hell, if it was easy it wouldn't be interesting.
George