Installing cut lenses in my headlights

[m3f_djjvr_d625d979e9]

So I came across another forum member who had cut low beam lenses installed in his headlights and thought "hey I think that's cool, I want those myself". So I ended up buying a pair of lenses from him and install them into my headlamps. I can certainly see right after the install a "cleaner" distribution of light onto the road, as well as a slight increase in brightness. They also look cooler imo.

In regards to the install I found it to be a pretty straight forward process, but cutting out the silicone from the last set of lenses is a little annoying. Other than that though it took maybe 45 minutes for both lights.



TL;DR Cut low beam lenses, looks better imo.





Pic before.

http://i.imgur.com/6cadXl.jpg



http://i.imgur.com/hvUxOl.jpg







Pics after

http://i.imgur.com/hSDGwl.jpg



http://i.imgur.com/m7qO3l.jpg

[m3f_Richardspe_ff9fba485e]

WTF are cut lenses?

[m3f_djjvr_d625d979e9]

As stated from BF.C

"Anytime you pass a light source through thick glass it's going to scatter the light and create a blurry cut off and light escaping above the cut off (not good for oncoming drivers). Now with the ellipsoids, you are doing that with TWO thick pieces of glass and one having flutes."

It just makes the light output cleaner/clearer.

[m3f_hcaleman_e2771eaa1d]

Did he just cut holes in the lenses? The OE ellipsoids glass is not fluted in directly in front of the projector, just at the periphery. I don't know about this one, but I like the stock lenses and think it would be hard to improve upon the complex optics as is.

[m3f_fiveightan_7e37700daf]

I've found the difference to be minimal with stock halogen projectors. But theoretically there should be some level of benefit to it, so props for going through the trouble.


From my experience a 3" hole saw bit made for glass works perfectly. I did this by securing the lens concave side up and filling it with a soapy water solution. A drill press obviously makes things easiest, but I did it by hand. Go SLOW and use minimal pressure. Taping the glass from both sides will minimize edge chipping as you cut. With glass going very slow is the key. It also makes the most horrible noise imaginable.


After cutting them, I actually just run without inner lenses. But I keep the lenses with holes cut in them around just in case.

[m3f_djjvr_d625d979e9]

I thought about running without the inner lenses period, but thought it might look a little weird on my car.

[m3f_fiveightan_7e37700daf]

I thought about running without the inner lenses period, but thought it might look a little weird on my car.


No lenses (TSX retrofit, but the projectors are in the same place as the stock ones...it's just missing the little chromed fins).


http://i103.photobucket.com/albums/m158/fiveightandten/M39.jpg


http://i103.photobucket.com/albums/m158/fiveightandten/Calander3.jpg

[m3f_djjvr_d625d979e9]

That actually doesn't look too bad. Though since I already put in the cut ones I'll stick with that.

[m3f_greyflyer_a37cb895c4]

Wait.



You guys took a hole saw to your headlights? On purpose? Damn I thought I lived in redneck country. This belongs on thereifixedit...

[m3f_fiveightan_7e37700daf]

Wait.


You guys took a hole saw to your headlights? On purpose? Damn I thought I lived in redneck country. This belongs on thereifixedit...


I also went to a junkyard and ripped the headlights out of an Acura TSX, and ripped the projectors out of those...and replaced my perfectly functioning halogen projectors with the wrong ones...and bolted them in with brackets that I fabricated from sheet metal I got at Home Depot. I cut that **** with a Dremel tool! And it's all held together with nuts and bolts I got at the hardware store. They don't have roundels stamped on them!


That must have been where I went crazy. After all that work, I tried a few different options in search of something aesthetically pleasing that didn't reduce the functionality of the upgrade I just made. Very red neck indeed. :thumbsup2:

[m3f_cracky_88af6b7d5a]

Wait.


You guys took a hole saw to your headlights? On purpose? Damn I thought I lived in redneck country. This belongs on thereifixedit...


theres no way a redneck would ever do this because it actually has function.


You can run without the lenses ...theres a million and one shrouds one can find out there (Ebay, retrofit source etc) if you want to clean it up a bit/make it have a bit more finished look. up to you.


I still need to finish my s2k retro on this thing. I was going to leave my lenses completely alone... but Im sort of having second thoughts. I want to keep that s2k drastic cut off as sharp as can be.

[m3f_greyflyer_a37cb895c4]

I also went to a junkyard and ripped the headlights out of an Acura TSX, and ripped the projectors out of those...and replaced my perfectly functioning halogen projectors with the wrong ones...and bolted them in with brackets that I fabricated from sheet metal I got at Home Depot. I cut that **** with a Dremel tool! And it's all held together with nuts and bolts I got at the hardware store. They don't have roundels stamped on them!


That must have been where I went crazy. After all that work, I tried a few different options in search of something aesthetically pleasing that didn't reduce the functionality of the upgrade I just made. Very red neck indeed. :thumbsup2:


LOL. By the power vested in me as a born n' raised georgia boy, I hereby grant you the title of honorary redneck with all the titles and privileges therein.

[m3f_fiveightan_7e37700daf]

theres no way a redneck would ever do this because it actually has function.


You can run without the lenses ...theres a million and one shrouds one can find out there (Ebay, retrofit source etc) if you want to clean it up a bit/make it have a bit more finished look. up to you.


I still need to finish my s2k retro on this thing. I was going to leave my lenses completely alone... but Im sort of having second thoughts. I want to keep that s2k drastic cut off as sharp as can be.

You can see a difference with a sharp setup like that. When you install, leave one in and one out. Cover the lights up (or unplug them) one at a time and have a look.


The problem with cutting a hole in the inner lens with a xenon retrofit is that the xenon projectors have a wide enough spread that the glass will still clip it on the side unless you cut a seriously big hole. This will depend on how far forward you mount your projector.


An option i've explored is this....


http://i103.photobucket.com/albums/m158/fiveightandten/Picture1-8.png


I didn't care for it aesthetically though, so I just stuck with the sans inner lens approach you can see in the pics above. But it is possible to space the projector forward enough to mount it flush with the lens like that.


Here's a better shot of what it looks like...


http://cache.gizmodo.com/assets/images/8/2010/01/uls_rnb5wm4.jpg

LOL. By the power vested in me as a born n' raised georgia boy, I hereby grant you the title of honorary redneck with all the titles and privileges therein.

**** yeah :beer:

[m3f_djjvr_d625d979e9]

^ Oh man! :rofl3:

[m3f_greyflyer_a37cb895c4]

FWIW I don't care about using gen-yu-wine BMW parts - if something's better, go for it. Hell I'm the guy who built a frame of 4x4s to change out motor mounts on a 928. Just seems hack(saw)ish to cut up a headlight lens when there are many options for truly better lighting, that don't cost a ton.