In that spot, the cutoff was tolerable. Height was OK. Not great for high speed night running, though.

The worst restriction was the cover. A good percentage of the light is reflected uselessly into the fender. If you can make a sort of surround, instead of a cover, with the glass lens exposed... (The 50mm is waterproof.)

If you do have a cover, a fender shield is important. (I didn't, and had to clean the inside of the cover frequently.)

All three of the attachments on mine were adjustable?


Note that I don't have the blue car ('85), anymore.

 

What about mounting that projector bulb down in the well but angle it backwards to a small mirror that would reflect the light forward? I suspect it would not take a very big mirror and could be made more aerodynamic.

 

Like Dr Nick's example?



I'd think that would work, but a clear cover would help protect the light.

 

I forgot about Dr. Nick's! I think I would mount it higher, and paint the surround silver. (He may have brought it forward to clear the ABS pump/fender liner.)

A cover that would be more vertical in front of the lens would cut down on the reflection also?

 

Well these included adjusters can't possibly work, it seems like a mistake but here's what you get:
1-screw adjuster
2-rigid mounts. These have a heavy knurl and the plastic bit is forced on.

This can only provide one plane of adjustment. I don't understand what they are thinking here.

So forget those useless adjusters. I never even liked the normal kind with 2 screws that move on odd planes so I'm designing something new that will be intuative to adjust.

 

It might be irrelevant, but there is a Swedish company that offers a pretty good solution to increase head light capacity without interfering with aero:

http://www.rayzerwidebeams.com/

 

If the 928 look (pop-ups) isn't important and you want functionality yet retain a legal height then reconsider the Fiat headlight conversion. These were cheap cars in Europe and I am sure the UK junk yards have them for less than $100.

Fiat Headlights 2.jpg

 

Well, here's the new light ready for some testing. Removing the adjuster bracket allowed me to make a new mount that doesn't poke above the light itself.
If the road coverage is good than it will get some kind of cover that allows the light to protrude.

 

I see some pretty aluminum!!

 

That looks like a good start. You didn't include a profile shot from the side. Does the top of the
light extend higher then the contour of the fender? If not, then the cover could follow the lines
of the fender. It'd be nice if it could be kept flush so as not to disrupt the aerodynamics.

 

Wish I could do machining like that!

You may want to mount the module as high as possible for the best angle to ground, but if you need to, for the cover's sake, you can lower it at least an inch, it looks like.

Because of the low beam cutoff shield, usuable light only comes out of the top half of the lens. IOW, the lower half of the lens can be be covered.

 

Okay Mike, when do the kits go on sale?