R8 PROJECTOR HEADLIGHT PROJECT - (Don't hold your breath)

Done anything to upgrade or personalise your 200 or 400? Wanting some advice on upgrades? Then talk about it in here.

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ROVER-25X
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R8 PROJECTOR HEADLIGHT PROJECT - (Don't hold your breath)

#1 Post by ROVER-25X » Thu May 02, 2019 12:34 am

R8 PROJECTOR HEADLIGHT PROJECT


I haven't done a headlight upgrade project for a long time, last ones I worked on were the headlights
on my 200 Bubble, I removed the orange lenses and painted the interior chrome trim black to get a
nice OEM looking smoked headlight design.



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I am hoping to apply this mod to my R8 Cabby headlights as I think it would be a nice subtle effect,
but with HID projector kits being very cheap these days compared to when I got my first kit in 2009
I though I might attempt to fit one of these kits too, yeah the beam refractors on the glass may be
an issue but at least its worth a punt, at least they wont blind oncoming drivers like most HID kits
do, this is the beam pattern on my MGF projector headlights.




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If the beam pattern is effected because of the glass I may attempt to find someone to make a set of
perspex covers based of a mould of the OEM glass to replace them, it should be a nice upgrade for the
look of the R8.


So far I have started stripping one spare headlight 1234dist kindly donated to the cause.

I baked it in a preheated 140'c oven for 5 mins to soften the adhesive, then I gently prised the glass
lens off, be careful not to force it as it can sent glass chips off at you, slow and steady.

Once off you can see the light is comprised of a one piece twin reflector unit and a chrome trim piece.





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To remove the trim piece is just a matter of freeing 6 clips, 2 of them though, one top and one bottom
are sealed in place with the original glass sealant, using a thin flathead screwdriver you can scrape it out
of the way to free them.




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The next step is to sand, prep, prime and paint the chrome trim, i'm not sure yet if I should paint it
matte black like the MGF and 200 bubble lights or gloss, the latter may show through it better though.

I'm not sure if I should paint the dipped reflector bowel or leave it chrome, as pictured below it is the
dipped bowel that houses the sidelight but I have an alternative LED idea I am pondering or even
relocating the sidelight to the main beam bowel.



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But that is where I am so far, a little more stripdown on the light is required to remove odds, ends,
fittings and the reflector bowels, anything to pass the boredom at work I guess.
:D :laughing2



Let me know your thoughts or suggestions folks. Image
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Re: R8 PROJECTOR HEADLIGHT PROJECT - (Don't hold your breath)

#2 Post by ROVER-25X » Thu May 02, 2019 1:05 am

I have finished stripping the headlight down, not much to it. :D


Wiring loom removed.




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Chrome trim on its own.





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The reflector bowel just needed popping off its two balljoint bars, I suspect a clip is missing off this bit though.




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Coming apart quite easy so I hope this assists anyone else attempting to strip one down. :clapping
ROVER-25X (2001 1.4 ROVER 25)
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Re: R8 PROJECTOR HEADLIGHT PROJECT - (Don't hold your breath)

#3 Post by Vinny1979 » Thu May 02, 2019 7:40 am

Fantastic
Was looking at doing this
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Re: R8 PROJECTOR HEADLIGHT PROJECT - (Don't hold your breath)

#4 Post by Johnny 216GSi » Thu May 02, 2019 2:57 pm

ROVER-25X wrote:
Thu May 02, 2019 12:34 am
Let me know your thoughts or suggestions folks. Image
Just struck me - could you do something very creative with the surround?

Like right on the leading edge all the way round, drill some equally spaced holes and poke small bright-white LEDs through and wire up in serial and parallel with ballast resistors so you get an outline of white dots around the headlamp, effectively making the headlamps have integral daytime running lights?

Is it range rovers that have this (and probably many other makes I suppose)? I remember Jeremy Clarkson's Comment on Top Gear - he said it makes the car look like a council house at Christmas!

Don't ruin the surround on my behalf. But if I had a spare headlight and I'd got that far with dismantling it, that's what I'd be trying...
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Re: R8 PROJECTOR HEADLIGHT PROJECT - (Don't hold your breath)

#5 Post by ROVER-25X » Mon May 06, 2019 12:51 pm

You could save yourself a soldering session and just stick flexible LED strips on it, I did this
on my MGF Headlights while experimenting before I finished projector unit, old photos from
2009 but even then the LED's were super bright, I beat a lot of manufacturers to it.




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Re: R8 PROJECTOR HEADLIGHT PROJECT - (Don't hold your breath)

#6 Post by ROVER-25X » Sat May 11, 2019 11:51 pm

UPDATE 11/05/19



I have been passing the time at work getting the surround trim prepped for paint, very easy to do, the
chrome is VERY thin, a slight rub with 1200 grit almost completely removed it, quick wipe down with a
bit of Methylated Spirit and a cloth to remove grease and chrome dust and its good to go.




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First light coat of Primer, I use U-POL, its good stuff.



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I put on another coat and once it dried I made a start on the HYCOTE Gloss Black, I recommend this
spray very much but apply it VERY thin as it is prone to runs.



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Second coat.



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Quite happy about how it turned out.




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I'll get the headlight back together for a test fit and upload tomorrow night. :D
ROVER-25X (2001 1.4 ROVER 25)
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Re: R8 PROJECTOR HEADLIGHT PROJECT - (Don't hold your breath)

#7 Post by Vinny1979 » Sun May 12, 2019 10:01 am

superb
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Re: R8 PROJECTOR HEADLIGHT PROJECT - (Don't hold your breath)

#8 Post by ROVER-25X » Mon May 13, 2019 1:31 am

Well tonight at work I got the surrounds fitted.



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Now to offer up the glass for the finished effect.
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Re: R8 PROJECTOR HEADLIGHT PROJECT - (Don't hold your breath)

#9 Post by ROVER-25X » Mon May 13, 2019 1:40 am

SURROUND TRIM FINISHED !

BEHOLD, THE TROPHY STYLE R8 HEADLIGHT (c)






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Let me know what you all think of this first stage of my Projector Headlight Project, I think I might edit
this part into a guide for people who just want to paint the trim surrounds and name it accordingly so it
is easier to find on the search box.
ROVER-25X (2001 1.4 ROVER 25)
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Re: R8 PROJECTOR HEADLIGHT PROJECT - (Don't hold your breath)

#10 Post by Vinny1979 » Mon May 13, 2019 9:27 am

Looks great
Are you doing the reflector bowl black too?
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Re: R8 PROJECTOR HEADLIGHT PROJECT - (Don't hold your breath)

#11 Post by Johnny 216GSi » Tue May 14, 2019 11:07 pm

Makes the glass look a bit tinted / smoked. Quite like it so far.
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Re: R8 PROJECTOR HEADLIGHT PROJECT - (Don't hold your breath)

#12 Post by ROVER-25X » Sat May 18, 2019 9:14 am

Thanks chaps. :D

I don't think i'll bother Vinny, as you can see below it isn't required i'd say. Image
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Re: R8 PROJECTOR HEADLIGHT PROJECT - (Don't hold your breath)

#13 Post by ROVER-25X » Sat May 18, 2019 9:43 am

The FIRST R8 PROJECTOR HEADLIGHT PROTOTYPE is FINISHED ! (....for now)



Well phase one of this project is completed, my cheap-o Projector units have arrived and I have fitted
it to my freshly painted headlight, as you can see below the unit comes in two parts, the main projector
housing and its chrome cover, it also has a couple of adapter plates included to adapt it to a H4 or a H7
headlight, it also has the option to wire up the pre-fitted solenoid to use it as a dipped main beam unit
but as the R8 has a separate main beam I won't use this, yes I know that the dipped lights on the R8
uses a H4 bulb that also doubles as a main beam too but 4 bulbs is a bit over kill even for ROVER. :laughing2




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To fit it to your headlight reflector it basically sits in where the H4 bulb goes, it may seem too heavy to be just
supported by the reflector but I have fitted these to several sets of headlights and run them with no issues, just
keep an eye on your beam levels by facing a wall at night.

You first need to remove the mounting plate for the H1 HID/Xenon bulb, it is only held in with 3 small screws and
then undo the nut washer if it is attached to the threaded shaft, sometimes they are and sometimes they are in
the bag with the adapter plates, you also need to remove the chrome plastic surround, mine came with no screws
fitted, these projectors were only £15 posted so i'm not complaining and I could find alternative small screws to
fit them but it won't fit inside the R8 headlights anyway so it is no great loss.



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Next fit the projector unit into the headlight reflector from the front, it has 'TOP' stamped on it so you can fit it in
the correct way up, feed the high beam wires through as well, you can cut these off if you want but I have retained
them in case I decide to use this function, there is just enough of a gap to feed the wires through the locating slot
of the adapter plate, if yours is a bit anorexic or at risk of being stripped just file it a little.

Once in position and by holding the projector in place slide on the white rubber gromit and the H4 adapter plate, it
is easy to see which way up it goes as it sits in place of the OEM bulb, next screw on the nut washer, then once it is
up against the plate firmly push against the projector but not too hard so you can do up the nut tight enough to stop
it moving about, then screw on the HID bulb plate.



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Now this is just the first phase of this project, I intend to fit some LED strip lights to emulate DRLs and the sidelights
before refitting the glass, like all the other headlights I have modded I will scrape off as much of the old sealant as I
can and apply a bead of Windscreen Sealant around the headlight housing then refit the glass, it is what I have always
used and gives a great seal but that will be done later down the line, use silicone at your own risk as it may not 'stick'
the glass to the housing and you may be at risk of it falling off while driving.

For now I have placed the glass in place for your viewing pleasure until I get some other bits and bobs sorted, I need to
order some bulbs, only £7 for a pair of 4500k (White) HID bulbs, once they arrive I shall conduct some lighting tests and
see what the beam pattern is like then inform you all with more photos.



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Let me know what you think so far folks, I think its going quite well, it has a stealth look. :D
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Re: R8 PROJECTOR HEADLIGHT PROJECT - (Don't hold your breath)

#14 Post by 1234dist » Sat May 18, 2019 10:38 am

Power up....really wanna see it now as it’s stealth af
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Re: R8 PROJECTOR HEADLIGHT PROJECT - (Don't hold your breath)

#15 Post by Vinny1979 » Sat May 18, 2019 6:25 pm

superb
1993 Rover 220 GSi Turbo , 2005 MG ZS 180 mk2

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