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First I fitted the headlight into the fender and fixed it in the correct position with tape and carefully made adjustments to the "hole" in the fender to get the mating surface between the light and fender to be perfect. It was not from D9 so I had to add material using 3M fibre glass filler. At this stage I also did alot of work on other areas of the fenders to get them to fit in a factory manner which is all I would be happy with.
In this pic you can see another area of the fender that ha to be adressed to get a good fit. Since the fender was "to short" the panelgap against the doors was to large. I had to apply material to lengten them to get the correct gap.
After I had finished the mating surface for the headlight I had to fabricate a receptor for the light unit and I wanted to use all the fasteners like on the 993 to get the same function as those cars.
I made a receptor from aluminium with the same ID as the 993 buckets. I fitted all fasteners to the light when they were fixed in the fenders and then I just shaped the receptor to fit the light unit.
Receptor finished look after paint.
Sheetmetal in body behind headlight has to be trimmed in order for the headlight to fit. I made some cuts and bent the metal away a bit so if I ever want to return to stock it will be easy.
Peder love the look of those lights and fenders. What great fabrication work and detail !
Thank you, I am happy with the result😊
After The fiment of the receptor and all fasteners was completed and I got the car back from paint my attention turned to the light unit itself and to what was needed to get them to aim correctly.
Since the headlight now sits alot lower than on a 993 the adjustment alone will max out and the aim will still be to high.
That meant I had to modify the light unit in several places to get a new baseline setting so the adjustment screws could still be used as they were designed to be functioning.
First I shimmed the light becel with a nut about 6mm so it aimes alot lower than stock, see pic.
After I shimmed the light bezel a new issue needs attention. The bezel now interferes with the inside top of the headlight housing. This meant I had to remove material from the bezel holder to make more room so that correct aim can be set. This pic shows what I did.
Finally I drilled a hole in the reflector and added the parking light there. In this pic you can see the little bulb inside the light unit.
So to summarize. It is possible to get it to work with D9 fenders and 993 headlights but definitely a BIG job. But I hope that my tips here can help anyone that is thinking of going down this road.
I really like the look and think this is how the 968 should have been made from the start. It is also alot simple and lighter!
10-02-2019, 04:11 PM
