Thread: Spyder Headlight Retrofit/Redesign

Never thought I'd find these in the junkyard! Thanks to row52.com I got a notification on my phone of a grand prix in my local pick-n-pull with a front picture and saw these, so I rushed over there and fortunately was the first one to grab them!




I noticed that either a factory uv coating was causing the fade and peel or some clear coating applied by the prior owner so I'm going to have to wet sand and polish them but that's not an issue.

These headlights are notorious for being super dim so I wanted to take them apart to see why. Here's the initial breakdown



Here's the stock projector removed



Here's why these projectors are dim....







Also, the halo rings are extremely dim, so I wanted to figure out why. Turns out they use the cheap dual opposing 4mm leds and the ring is supposed to distribute the light.



Here's the completely deconstructed housings

[img]https://preview.ibb.co/nDgd4x/20180405_221351.jpg

Now on to the build! Well, It's apparent that the stock projectors are garbage, and the stock hi-beams are only pointable up and down, so my intention is to remove the stock bracket and place the old projector in the old hi-beam location while using a bi-xenon projector (dual lo/hi beam) in the stock location but allowing for greater adjustment.

As a mock up, I placed both old projectors in their locations as a test fit:



There are a few companies who make the adapters from spyder projector to morimoto mini h1 projectors, but at $55 plus shipping, I think I'll make my own from a sheet of aluminum or something. (link below)

Retro-Quik: Spyder Lights - Complete Retrofit Kits from The Retrofit Source

I plan on using a sequential switchback led to run part of my drl and my turn signal and shaping it along the top and arching around the front some.



I plan on re-wiring the stock turn signal bulb location for just a plain blue led that will come on with drl.

I also plan on having three halos, one for each stock bulb location that are controlled by the drl.

I will be using a series of load resistors to compensate for the decreased consumption of the bulbs.

I will be using Demon eye leds on both the old "dummy" projectors and the new ones somehow switched by drl but off when hi or lo beams are triggered.



I think I'm going to keep the parking lights stock though just to make everything legal. I thought about doing switchback halo rings with the turn signal, but I thought that might be a bit much since the drl strip already does that.

Those are my plans at the moment! I've got a few retrofits for other members going on that I might post here too, any input or just general thoughts or things related to projector retrofits or spyder headlights are always welcome! I hope these will turn out cool!

Well, Got most of the parts in! Still have a lot of prep work to do, but here's the general hashing out of the halos:



I'll black out the reflectors the old style halo's used and the former turn signal and probably secure with very thin wire. I trust wire over glue any day!

Yes, the lenses look like garbage right now, but here's where I plan on placing the switchback led strip. I like the location. Might shift it to after the accent leds though, still deciding.



I'll be blacking out this reflector, it used to be the turn signal. Instead, I'm going to run this accent blue led "lens" bulb to match the double projector.



The demon eye leds are going to take the longest to ship. If I like the look, I'll use them on both sets of projectors.

Should be starting to test fit everything tonight as long as the projectors are quality enough to use. The factory spyder headlights were so bad though, I don't think that'll be hard to beat!

Update:

For anyone wanting to try this, the spyder retrofit bracket that trs and others make does not work because of how our high beam bracket is held on. The offset is completely different. That being said, I wasn't giving up that easily! I picked up a thin sheet of aluminum and took several measurements and tried a few designs until I found one that would work. Here's the pattern that I ended up using:




Now, I'm no master fabricator and I used all common hand tools to cut it out, so don't be too discouraged. Here's a closeup of the bracket mounted along with the highbeam:





Now, I'm probably going to get some flack for doing this, but I've never trusted glue or epoxy to hold halos and other stuff. I've had it come off way too many times, and plastic like fishing line can melt or get brittle over time, so I opted to use some really thin picture hanging wire to secure everything. I will be going back and painting it, this was just the general mockup of everything put on for the first time:



A few notes on this build. There's literally 1000 different ways you could make the bracket, or design these lights. This was just what I chose, so feel free to do it your own way. I chose to keep the high beam stock location even though I'm using a hi/lo projector just for asthetic reasons. I plan on putting an accent bulb in there, or I could be super obnoxious and run two high beams or something else custom.

In case anyone was wondering about the "second projector", I disassembled the stock projector and folded the bracket in on itself to hold the lens in, and it was just the right size to push up and stay in place where the high beams used to go. I thought this looked cool so I kept it since this spot is essentially useless anyhow.



Still waiting on some accent leds to come in, so I'm still perfecting things. More to come!

Finished up the semester and cramming for finals delayed me a bit on working on the project (that, and getting a project car for my wife but more on that in other threads!)

I'd been putting off restoring the lenses, but finally bit the bullet. Started trying to restore by hand, but several hours in, I realized I'd have to enlist the help of my drill. Ended up having to take them down to 150 grit all the way up to 3000 before polishing. The cracks in the outer layer went beyond the uv protective coating that was peeling, so I had to sand down quite a ways. They didn't come out perfect, and eventually I'll probably buy another set of spyder headlights just to fix that, but here they are:



Just about the only thing I'll need to figure out before putting things together is how to fix these mounting tabs. I was thinking of using thin sheet metal and using some sort of epoxy, but I can't think of a really good fix. Hopefully someone will chime in! Here's the damage:





Once I get the tabs fixed, I'll point in the projectors just to make sure the fit is right, then I'll begin putting everything together and testing. Not trying to seal these things up and have to take them apart again!

Well then, that's a lot of work I'm anxious to see how they work

Originally Posted by selliott

Well then, that's a lot of work I'm anxious to see how they work

haha thanks man! Yeah. Looking back, I probably should have just retrofitted a set of stock headlights instead, but hey, if they work, they'll look really awesome!

Originally Posted by Bronco Boy

I've had good success with the 2 part plastic bonders. The last one I used was JB Weld.
Plastic Bonder Syringe


| J-B Weld

Thanks bronco! I actually decided to be brave and try plastic welding for the first time! Bought a cheapo from harbor freight for $15, and cut some polypropylene from the stock airbox I had lying around which was nice and thick. Used the mesh that came with the kit to reinforce the weld. It's stronger than the entire tab now! I might have to go back and add some braces to the bracket since I can literally weld to almost anywhere on the headlight. Not the best looking solution, but it works!



Tomorrow, I'll re-wire the harnesses so I can test them out of the housing and point them in. Once I have a baseline for what angle they need to be in, I can finish modifying the housing to make them work and re-seal them finally!

Originally Posted by BANDIT

*EDIT* You posted your solution to the problem while I was figuring out my reply.
If the tabs are ABS you could try this method
How to Fix a Motorcycle Fairing for less than $10 - YouTube
I used it to fix my fairing and it works, I did however reinforce the inside with a piece of 1/8 ABS sheet that I got online through Amazon.
Seeing as you like to create most of your own stuff I thought this would work for you.

haha thanks bandit! I was really glad that method worked for me. I was definitely worried, but now I want to fix everything plastic! haha

Originally Posted by ItHurtz

Classy has done quiet a few spyder retros they look badass. I prefer the spyder retro looks over the stock anyday.

The 97-03 were never dim those were the 04+. Mine were bright as hell could see for a mile. I tried to retro them and broke em haha. I will live through you

Yup! That's actually where I got my idea from. They're not fun to retrofit, I've been extremely lucky. You might have jinxed me though! Still have a ways to go! lol

Well, got time to do some work on them today! Mounted the headlights with just the base layer and projectors to get a feel for the aiming. Turns out since I'm fitting MUCH larger projectors than stock spyder, there's not much room for aiming. All in all however, got everything aligned, so I cleaned everything up and re- sealed them. I'm a bit concerned with them leaking since they're a bit akin to a stuffed turkey (and almost as heavy!).

Haven't got a chance to finish the accessory wiring or install them, but hopefully tomorrow is judgement day!

P.s. for the discerning eye, yes, there's definitely a fair bit of flaws, but they're for me, and I can a always go back and fix stuff!

Originally Posted by ItHurtz

that turn signal...... now thats weird

haha yup! I saw it and instantly felt like nightrider had sex with an Audi, so naturally I'm game.

Good job

Originally Posted by selliott

Good job

thanks man! We're going after your lights soon!