Euro headlight surgery

We want Tri-bar DRLs right? I've spent a lot already on bits to Americanize my euro Mustang and decided to do the DRL fix myself to save some money. My car is still sitting on the dock in Baltimore, but I'm happy to contribute my progress so far back to the community.

Here's a US headlight I cut open to get an idea of how I would install the Diode Dynamics kit in my euro headlights once my car shows up. I chose to cut rather than pry open the headlight because it's easier & less risky. These things will be worth ~$1000AUD each as spare parts so I'd be upset if i cracked a clear lens.

I decided on using a hot knife because it's fast and doesn't make a mess. I would suggest using a butane soldering iron with knife attachment. I tried a cheap electric one, but the blade never really got hot enough. I wouldn't recommend inhaling the smoke while you cut.

The outer enclosure is made of Polypropylene and was easy to cut. The piece inside is polycarbonate which needed a bit more heat to get through and got all stringy and sticky. There's also alot of ribbing on this piece which is why my cuts zig-zag.

Because this is a US headlight, you can see the factory DRL boards already installed.

I intend to re-seal it by melting the plastic back together and then running black silicone over the seam. Based on what I've read in the service manual and on the Europe section, I'll be wiring these DRLs back to the washer motor and disconnecting the stock euro driving lights so they don't even have a change of accidentally lighting up.

Genuinely appreciate the efforts and thorough write up man. Will most definitely help some pro DIY-ers out there.

I think I'll stick to BoostDesigns and top up the $200 and let him do it lol

Good write up mate.
I cut all around light with a butane Dremel. It left a right mess.
Your way is neater because on back of the light.

Thanks a lot for the write up, after seeing that I am thinking that this may be the way to go also. Not sure how heat will affect the lense and what it will look like when resealed, the top edge is really noticeable with the bonnet open, the back is hidden.

I understand the first cut on the outer shell, but then you say you have a second cut and to be careful how deep you go. I don't understand what the second part is. Maybe it becomes obvious when you open the back up, can you explain this part a bit please?

HybridGT Have you had a reply from Boostdesigns, I sent him a message here and on facebok a few days ago but no answer:shrug:

I have tried a few headlight repair guys but no one seems to want to touch this job and I am not sending my lights to Poland, so may have to go DIY.

Think it's this bit, the bit the white defused screws to,

Frozen Pea, how did you go about getting the US headlights? second hand ?
Did you work-out it is cheaper to buy the whole headlight second hand rather than buy the DRLs as spare parts ?

tri-bars, parking sensors and a tow bar for the bike rack are my priorities when my car arrives.

Ian

Bingo. The white defuser is screwed into that piece. The idea is when cutting it from behind you take out the middle section, so that with two screws either side it remains rigid.

steerage250 said:

Frozen Pea, how did you go about getting the US headlights? second hand ?
Did you work-out it is cheaper to buy the whole headlight second hand rather than buy the DRLs as spare parts ?

tri-bars, parking sensors and a tow bar for the bike rack are my priorities when my car arrives.

Ian

Click to expand...

I found it on eBay.

You cannot purchase the genuine DRL lights as spares, they come as part of the headlight. I bought this: http://tinyurl.com/zljyrd2

If you watch the installation video on that product page, it will help to visualise the different components of the headlight i'm talking about above.

steerage250 said:

Frozen Pea, how did you go about getting the US headlights? second hand ?
Did you work-out it is cheaper to buy the whole headlight second hand rather than buy the DRLs as spare parts ?

tri-bars, parking sensors and a tow bar for the bike rack are my priorities when my car arrives.

Ian

Click to expand...

They already have parking sensors so you can cross that one off the list

Ian whu said:

Think it's this bit, the bit the white defused screws to,

Click to expand...

Hi [MENTION]Ian whu [/MENTION]
I have a silly question.
But is there the housing that the drl boards attach to?

It is yes

Ian whu said:

It is yes

Click to expand...

Brilliant, thank you.
I was sure that as no drl's no need for support housing, just the reflector.
The light at the end of the tunnel is getting brighter on this subject....:lol:

Gnome said:

They already have parking sensors so you can cross that one off the list

Click to expand...

so they have front and rear parking sensors - as well as the reversing camera?? (I've looked at photos of the Australian models and haven't seen the tell-tale little round sensors in the bumpers, and it wasn't mentioned on the window sticker, so I'd given-up hope).

I see you've actually got your car, so you ought to know

thanks

Ian

i believe there is rear sensors and reverse camera. No front sensors which SUCKS ASS!!!

Front sensors are a dealer fitted option, Xvision - doesn't hook up to the built in alarms so a separate on/off switch and beeper is mounted in the cabin.

http://www.xvisionsystems.com/Products/Front-Parking-Sensors/