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7" retrofit (GDAA WRX)

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  • Originally posted by gold94corolla View Post
    ^^^ wow no way, you seriously trimmed it like that? wow lol
    Yes. Nothing that a drill, a metal file, and a lot of manual labor can't do.

    I realize many of the shapes and cuts are bad from a mass producability point of view. But since a big part of this DIY was to pretend to be a craftsman (which is quite different from my daily job), the more complicated, the better. Why else would I have bothered to try to trim 3 lenses into a faceted configuration, and then abandon it...

    .. cause it seemed challenging.

    Originally posted by MGMTF View Post
    This is crazy, now I just need to order a second set of fog housings for my truck so I can compete in quad fogness haha.
    Sounds good. With a 7" face, You can actually fit about 4 Hella Micro DE foglights, or 3 ES300 foglights. So, if you use low beam projectors, not that I advocate that for a true foglight, you may be able to fit 2 at most.

    It may be easier to find a rally-style light pod so you can fit more:
    (from Tamiya's website http://www.tamiya.com/english/products/list/24car_5.htm)


    There are some generic light pods for trucks iirc.
    Jul 2012 ROTM (3-way quad headlight) ; Sep 2015 ROTM (custom muli-lens 7" fogs)

    3-way quad wiring; foreground limiter; squirrel finder;

    Comment


    • Pass through hole for mounting

      Now to make mounting holes for the white bracket to attach to the black plastic trim.



      To make it possible to place the nut and washer through, the hole on the upper part of the white bracket needs to be enlarged. The bottom hole on that same location remains the smaller size, which only lets the screw threads to pass through.


      Do another one.

      And mount the white bracket to the black plastic trim piece by mounting the screw upside down, and washers and nuts on top (through the enlarged hole on the upper part of the white bracket).


      The outer side looks like this, with 2 screws somewhat visible:


      But not as visible as my original version from ~10 years ago:
      Jul 2012 ROTM (3-way quad headlight) ; Sep 2015 ROTM (custom muli-lens 7" fogs)

      3-way quad wiring; foreground limiter; squirrel finder;

      Comment


      • Originally posted by satrya View Post
        Sounds good. With a 7" face, You can actually fit about 4 Hella Micro DE foglights, or 3 ES300 foglights. So, if you use low beam projectors, not that I advocate that for a true foglight, you may be able to fit 2 at most.

        It may be easier to find a rally-style light pod so you can fit more:
        (from Tamiya's website http://www.tamiya.com/english/products/list/24car_5.htm)


        There are some generic light pods for trucks iirc.
        I already have good size fogs on my truck haha. Also have ZKW projectors fogs and X5 LEDs to use. I will be starting a build thread for it in the next few weeks hopefully.
        '04 Silverado 2500HD CCSB
        Awaiting a Proper HID retrofit (RX350)
        '00 Corvette 6spd; FBO LQ9, FX-R 3.0 on 50w
        '94 Camaro LQ4/4L80e Swap; WR
        '93 W/T 1500 RCLB LQ4/4L80e Swap; Sealed 6

        Comment


        • A shot of the larger hole for accessing the actual hole where the screw & nut will go to:




          Wondering what to do with that bulge on the black plastic piece; It is formed because the plastic piece needs to bend slightly to follow the bumper cover's contour. It's not that obvious when seen from the outside, as it is usually somewhat hidden from a nearby pedestrian's pov:


          I'll leave it alone for now.
          Jul 2012 ROTM (3-way quad headlight) ; Sep 2015 ROTM (custom muli-lens 7" fogs)

          3-way quad wiring; foreground limiter; squirrel finder;

          Comment


          • Made a pair of mounting hardware to secure the black plastic piece on the inner bottom side. I took advantage of a vertical slot opening in the bumper cover. I could've just drilled the bumper cover, but I didn't want to impart visible & irreversible mods on my oem part (i.e. the stock bumper cover).

            Details of the mounting hardware are here:
            http://www.hidplanet.com/forums/show...a-slot-opening

            This is the conceptual look of the mounting hardware (using cardstock):


            This is the finished mounting hardware (galvanized steel), before the 2 forward facing tabs are bent to accommodate a mounting screw for the black plastic piece.
            Jul 2012 ROTM (3-way quad headlight) ; Sep 2015 ROTM (custom muli-lens 7" fogs)

            3-way quad wiring; foreground limiter; squirrel finder;

            Comment


            • Comment


              • He's like an Austrian clock maker...
                2000 Celica GTS 'slowest gts evar'
                1998 Mazda 626 FS-DE/CD4E 'mom-mobile'

                Comment


                • Originally posted by gold94corolla View Post
                  Does that come with butter?

                  Originally posted by Bitter View Post
                  He's like an Austrian clock maker...
                  I thought clocks are associated with Switzerland? Or maybe Shenzen?
                  Jul 2012 ROTM (3-way quad headlight) ; Sep 2015 ROTM (custom muli-lens 7" fogs)

                  3-way quad wiring; foreground limiter; squirrel finder;

                  Comment


                  • Heat gun 3D shaping time

                    Since I decided against wrapping the black plastic piece around the corner of the bumper cover, the overall shape of the piece is much closer to my original version from 10+ years ago.

                    I wanted to add more contour to the piece. Heat gun 3D shaping time. Having heat (& tear) resistant Kevlar gloves is a good idea. Start with the outer bottom corner. First 15-30 minutes yields a subtle rounding on that corner:


                    Another half hour working in that area deepens the 3D contour there:


                    Moving up on the outer corner:


                    A bit more (hard to see the difference other than the sore fingertips)...


                    Getting the outer, almost vertical corner, to match the existing opening's curvature takes a lot of heat-bend-wait repetition


                    At this point, the black plastic piece is held by the 2 tabs on top and rests on the floor of the bumper cover opening.

                    Next up, the driver side...
                    Jul 2012 ROTM (3-way quad headlight) ; Sep 2015 ROTM (custom muli-lens 7" fogs)

                    3-way quad wiring; foreground limiter; squirrel finder;

                    Comment


                    • Good luck lol
                      Originally posted by nine44
                      350 wit da wrist boy?

                      Comment


                      • Originally posted by Ilikecars View Post
                        Good luck lol
                        Thanks. Fortunately, this step only requires patience and some time to let the sore fingertips rest (from pushing the heated plastic piece in order to form concave profiles).
                        Jul 2012 ROTM (3-way quad headlight) ; Sep 2015 ROTM (custom muli-lens 7" fogs)

                        3-way quad wiring; foreground limiter; squirrel finder;

                        Comment


                        • Why not heat it more? Make it easier
                          Originally posted by nine44
                          350 wit da wrist boy?

                          Comment


                          • Because that hurts the fingers more. Also, it may damage the plastic.
                            Originally posted by Bitter
                            They're literally flying canoes with boxer engines packed full of Molotov cocktails that rely on tampons and $10 screws to stay in the air and not kill you.

                            Comment


                            • Originally posted by phantom240 View Post
                              Because that hurts the fingers more. Also, it may damage the plastic.
                              My thoughts exactly. Better to go at a longer temp and take longer than risk damaging the shroud beyond repair.

                              Originally posted by cthunder
                              The more you mod your car the moodier it gets.
                              Avalon Dual Lens | Rogue LED | Mori 3800K | Mori 3Five | H11 PnP LED

                              Comment


                              • Originally posted by Ilikecars View Post
                                Why not heat it more? Make it easier
                                Originally posted by phantom240 View Post
                                Because that hurts the fingers more. Also, it may damage the plastic.
                                Originally posted by Fstrsn View Post
                                My thoughts exactly. Better to go at a longer temp and take longer than risk damaging the shroud beyond repair.
                                Yes to all. I'm using the lower setting of my heatgun, and even then, the ABS plastic can start bubbling and deforming if it gets too much heat.

                                Plus the heat resistant gloves can only insulate so much.
                                Jul 2012 ROTM (3-way quad headlight) ; Sep 2015 ROTM (custom muli-lens 7" fogs)

                                3-way quad wiring; foreground limiter; squirrel finder;

                                Comment

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