993 headlight conversion
01-18-2015, 08:21 PM
#1
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993 headlight conversion
Was a 'hot topic' for sometime, then apparently fell by the wayside due to problems encountered.
One post in an unrelated thread had a photo by a lister here with a nce Blue example of the conversion.
Anyone have any more relevant information?
One post in an unrelated thread had a photo by a lister here with a nce Blue example of the conversion.
Anyone have any more relevant information?
01-19-2015, 02:02 AM
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hi Jay,
thanks for the pm..... in it, you mentioned a sawzall. yes, all the fun started with a sawzall!
on this page you'll find a discussion of my transmission mods,
https://rennlist.com/forums/968-foru...-968-a-11.html
but, post #154 on the same page might be nice place to start with respect to my fender/headlamp project....
from there, you'll see the photos over the next 4 pages, with some info,
and then adding something of a final summary on page 14. it's involved, but, overall, a fun upgrade.
feel free to contact.
od.
thanks for the pm..... in it, you mentioned a sawzall. yes, all the fun started with a sawzall!
on this page you'll find a discussion of my transmission mods,
https://rennlist.com/forums/968-foru...-968-a-11.html
but, post #154 on the same page might be nice place to start with respect to my fender/headlamp project....
from there, you'll see the photos over the next 4 pages, with some info,
and then adding something of a final summary on page 14. it's involved, but, overall, a fun upgrade.
feel free to contact.
od.
Last edited by odurandina; 01-19-2015 at 02:30 AM.
01-19-2015, 06:36 PM
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Thanks OD.
Looks like you managed to complete the head light transformation - looks really great! Any long term feedback now that you've had them for several months? Any lessons learned you care to share?
Looks like you managed to complete the head light transformation - looks really great! Any long term feedback now that you've had them for several months? Any lessons learned you care to share?
01-22-2015, 01:25 PM
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1. find two semi-destroyed 993 fenders with their front sections intact.
2. cut them about a foot back from the headlamp sockets.
3 trim the baskets of the 993 fender sections such that they can fit through the smallest possible hole,
but still retain their original function (supporting the Xenon headlamps) with your grinder.
4. remove the 968 headlamps.
5. using a grinder, cut openings varying from about 1/8"~5/8" around the original 968 headlamps sockets. here it is crucial to make
the expanded sockets just large enough to allow the 993 headamp baskets to pass through (but no larger).
6. cut perpendicular slits (running the length of the fenders) of varying lengths of about 6~18" of the both fender sections where they
will be joined.....(this will facilitate being able to allow the 968 fender section to rise/expand..... and the 993 fender section to descend/contract
where they will be joined.
7. tap down the lower section of inner the 968 fender's headlamp openings (to help form an even elevation where the front of the 993 fender
sockets will come to rest).
7. insert the 993 baskets through the 968 openings. line them up with great care and begin spotwelding.... remove the excess/redundant
sheetmetal with the grinder... (this process involves pushing the sections of the 993 sheetmetal down and bring the 968 fender up.....
naturally this is extremely involved.... naturally, you'll be cutting significantly longer sections on the 968 fender than the 993 fender.
8. add sheetmetal to fill the gaps.
9. spotwelding and grinding.
10. base resin: EPOXY or tiger hair and general sculpting. i used the cheese grater + 40 grit stuck to a 3"X12" wood block.
12. finishing resins (glorified thinned bondo and then thinner bondo) and..... my sculpting tool consisting of 80/220/500 grit stuck to
2 1/2"X10" blocks of 3/8" plywood.. here you will find your 'inner automotive soul' creating 2 identical fenders -or die trying.... my finishing
resins were thinned bondo applied/sanded maybe 15 cycles setting down resin/sanding, with maybe 20 more cycles of applying resin with
paper towel over foam brush, and more endless sculpting/sanding....
*alternate method: use 1 piece of clean sheetmetal to join a much smaller 993 front section to a smaller 968 rear section.
(i felt i lacked the skills to attempt this.... then risk destroying both sets of donor fenders).
2. cut them about a foot back from the headlamp sockets.
3 trim the baskets of the 993 fender sections such that they can fit through the smallest possible hole,
but still retain their original function (supporting the Xenon headlamps) with your grinder.
4. remove the 968 headlamps.
5. using a grinder, cut openings varying from about 1/8"~5/8" around the original 968 headlamps sockets. here it is crucial to make
the expanded sockets just large enough to allow the 993 headamp baskets to pass through (but no larger).
6. cut perpendicular slits (running the length of the fenders) of varying lengths of about 6~18" of the both fender sections where they
will be joined.....(this will facilitate being able to allow the 968 fender section to rise/expand..... and the 993 fender section to descend/contract
where they will be joined.
7. tap down the lower section of inner the 968 fender's headlamp openings (to help form an even elevation where the front of the 993 fender
sockets will come to rest).
7. insert the 993 baskets through the 968 openings. line them up with great care and begin spotwelding.... remove the excess/redundant
sheetmetal with the grinder... (this process involves pushing the sections of the 993 sheetmetal down and bring the 968 fender up.....
naturally this is extremely involved.... naturally, you'll be cutting significantly longer sections on the 968 fender than the 993 fender.
8. add sheetmetal to fill the gaps.
9. spotwelding and grinding.
10. base resin: EPOXY or tiger hair and general sculpting. i used the cheese grater + 40 grit stuck to a 3"X12" wood block.
12. finishing resins (glorified thinned bondo and then thinner bondo) and..... my sculpting tool consisting of 80/220/500 grit stuck to
2 1/2"X10" blocks of 3/8" plywood.. here you will find your 'inner automotive soul' creating 2 identical fenders -or die trying.... my finishing
resins were thinned bondo applied/sanded maybe 15 cycles setting down resin/sanding, with maybe 20 more cycles of applying resin with
paper towel over foam brush, and more endless sculpting/sanding....
*alternate method: use 1 piece of clean sheetmetal to join a much smaller 993 front section to a smaller 968 rear section.
(i felt i lacked the skills to attempt this.... then risk destroying both sets of donor fenders).
Last edited by odurandina; 03-08-2015 at 05:43 PM.
01-22-2015, 01:49 PM
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i'm glad i did this mod.... but, i'm not sure i'd want to do another set....
they're pretty good. it wasn't easy getting them there. so, i probably should have the fenders copied.
there's little reason to have anyone live through that again.
they're pretty good. it wasn't easy getting them there. so, i probably should have the fenders copied.
there's little reason to have anyone live through that again.
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03-08-2015, 12:49 AM
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Quick question. How do you change the bulbs when one goes out?
03-08-2015, 05:04 PM
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these are 993 lamps with their actual housings. simply, reach in and turn the levers (see 993 owners manual)...
they pop right out... disgustingly easy....
(the lenz' is surrounded by a rubber 0-ring that makes an H20-tight seal).
as you turn the levers, gently feed the lamp housings into their socket (lever grabs into a slot, pulls the lamps in - and forms a very snug seal and fit).
and for htf to avoid getting crushed by Porsche on the innards $$$.... see below.
simply, reach in and turn the levers (see 993 owners manual)... they pop right out... disgustingly easy....
(the lenz' is surrounded by a rubber 0-ring that makes an H20-tight seal).as you turn the levers, gently feed the lamp housings into their socket (lever grabs into a slot, pulls the lamps in - and forms a very snug seal and fit).
and for htf to avoid getting crushed by Porsche on the innards $$$.... see below.
update; got my 993 Xenons back from the car electronics guy recently;
effin' amazing's all i can say. cost comparison:
buy the factory Xenon Litronic lamps at the dealer (includes the bulbs and igniters) = $5,600
add on the ballasts and wiring harness' @ $1,400 >> = ~ $7,000 (total)
instead i found a pair of Xenon's on ebay from a guy who did a huge group buy for the 993 guys wishing to change over to the Xenons and he ended up with some overstock. no porsche ballasts, no porsche wiring harness... but the lampsets arrived at my house for $1,500 plus $40 shipping.
i was going to capitulate on getting the stock wiring harness and the ballasts until about a few moments later it dawns on my that if i want to run 6,000 k 35w lamps, i'll need a kit and then the Porsche wiring harnesses and ballasts aren't needed WIN !!!
so i brought the lamps in and told him i wanted the 6,000 k Phillips bulbs and call me when they're ready. he retofitted a complete kit and sealed up the new wiring harness;
6,000 k/35W are 100 % street legal,
total for new genuine Bosch fixtures + AFTERMARKET Phillips 6,000 k lamps/igniters/ballasts; $1,886.
leftovers; original bulbs and igniters. sold to a 993 guy).
effin' amazing's all i can say. cost comparison:
buy the factory Xenon Litronic lamps at the dealer (includes the bulbs and igniters) = $5,600
add on the ballasts and wiring harness' @ $1,400 >> = ~ $7,000 (total)
instead i found a pair of Xenon's on ebay from a guy who did a huge group buy for the 993 guys wishing to change over to the Xenons and he ended up with some overstock. no porsche ballasts, no porsche wiring harness... but the lampsets arrived at my house for $1,500 plus $40 shipping.
i was going to capitulate on getting the stock wiring harness and the ballasts until about a few moments later it dawns on my that if i want to run 6,000 k 35w lamps, i'll need a kit and then the Porsche wiring harnesses and ballasts aren't needed WIN !!!
so i brought the lamps in and told him i wanted the 6,000 k Phillips bulbs and call me when they're ready. he retofitted a complete kit and sealed up the new wiring harness;
6,000 k/35W are 100 % street legal,
total for new genuine Bosch fixtures + AFTERMARKET Phillips 6,000 k lamps/igniters/ballasts; $1,886.
leftovers; original bulbs and igniters. sold to a 993 guy).
Last edited by odurandina; 03-08-2015 at 05:36 PM.
03-08-2015, 09:42 PM
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Man that is a great looking mod - you really really really need to get those templates made for the rest of us mere mortals.
03-08-2015, 10:17 PM
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btw OD - my mind is still reeling from the detail in your post.
Can you please explain to this imbecile the conversion? Not sure that I understand and I've read it through a couple of times.
Can you please explain to this imbecile the conversion? Not sure that I understand and I've read it through a couple of times.
03-08-2015, 10:45 PM
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these are 993 lamps with their actual housings. simply, reach in and turn the levers (see 993 owners manual)... they pop right out... disgustingly easy.... (the lenz' is surrounded by a rubber 0-ring that makes an H20-tight seal). as you turn the levers, gently feed the lamp housings into their socket (lever grabs into a slot, pulls the lamps in - and forms a very snug seal and fit). and for htf to avoid getting crushed by Porsche on the innards $$$.... see below.
simply, reach in and turn the levers (see 993 owners manual)... they pop right out... disgustingly easy.... (the lenz' is surrounded by a rubber 0-ring that makes an H20-tight seal). as you turn the levers, gently feed the lamp housings into their socket (lever grabs into a slot, pulls the lamps in - and forms a very snug seal and fit). and for htf to avoid getting crushed by Porsche on the innards $$$.... see below.
03-09-2015, 04:08 PM
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yes, the Xenon lamp housings are a good deal more involved.
in my case, I went with 6000k vs 4300k for a not-too-ricey blue hue mixed in the bright white.
I think 8000 k looks even better but definitely well down the ricey slippery slope....
many 993 guys go all the way up to 12000k/75w. which look amazing, imo.
but for me, just a hint of blue is perfect. the legal limit is 6000k.
in my case, I went with 6000k vs 4300k for a not-too-ricey blue hue mixed in the bright white.
I think 8000 k looks even better but definitely well down the ricey slippery slope....
many 993 guys go all the way up to 12000k/75w. which look amazing, imo.
but for me, just a hint of blue is perfect. the legal limit is 6000k.
03-10-2015, 08:40 PM
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yes, the Xenon lamp housings are a good deal more involved. in my case, I went with 6000k vs 4300k for a not-too-ricey blue hue mixed in the bright white. I think 8000 k looks even better but definitely well down the ricey slippery slope.... many 993 guys go all the way up to 12000k/75w. which look amazing, imo. but for me, just a hint of blue is perfect. the legal limit is 6000k.
03-10-2015, 10:45 PM
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Looking closer at your pics, it looks like you had to meld in more than just the top portions of the fenders.
It looks like the guides were added as well as the portions just inside the engine compartment where the headlight lock/latch is located - if so, how did you go about this?
It looks like the guides were added as well as the portions just inside the engine compartment where the headlight lock/latch is located - if so, how did you go about this?