My friend's supervisor found a picture of an R33 with some weird headlights and thought they were cool. My friend (Paul) suggested he ask me if I could make something similar since he couldn't find anywhere that sells them. Some of you may have seen the Nemesis R33... those are the headlights.
This guy really seemed to want them for his car, so I agreed to make them.
I couldn't find any information on the car, just two pictures of it (until now, when I found two more)so I just decided to figure it out for myself.
I told Paul to grab some headlights and some lights to fit inside of them.
He came back with these.
Stock r33 kouki (i think) headlights
Some fog lights from upgarage. These lights are angled, so they'll be a little different by the looks of it. It seems the lights on the nemesis 33 are flat.
He also picked up a 3 foot pvc pipe, about 9cm in diameter to make the tubes.
First, I threw them in the oven for about 5 minutes @ 350*F, then pulled them apart.
Pulled the reflectors out of the housing and the black trim off the lens.
Traced the PVC pipe on the lens where I wanted to put the openings.
This was the first measurement 4cm space from the grill side, 1cm from the bottom. After testing it out, I adjusted it to 2cm up since the lens wouldn't go back on with the light sitting that low.
Just an idea of how it would sit. Originally I was going to have the angled the way they are in this pic, but decided to angle them the other way for looks and so more light goes in front of the car than on the side.
Cut out the lens ( a little choppy, but done) and cut a few sections of the PVC pipe.
From here, I had to pause on the lens so I could get the lights mounted in the housing, then measure the tubes, cut and mount them.
Cut the housing to allow access to change the bulb.
Mounted the first light.
I used some of the universal brackets to mount them.
I bent them into place and did a few slight adjustment to make sure the light lined up with the hole in the lens.
Mounted the second light.
All three lights mounted.
I decide to angle the outer light out just a bit to make sure some light got out to the side of the car. I haven't seen these lights on at night before, so I don't know how well the aim will be.
Showing all the material cut out of the housing. I made sure to leave enough material around all the mounting points so they wouldn't just break going down a bumpy road or something.
Paul came over to test the new HIDs. The center will be the low beam HID, the left (in picture) will be a bright parking light, and the right (in picture) will be the high beam.
That's what he told me at least, I'm not doing any of the wiring, just the assemblies.
I decided it would be best to plastic weld the tubes onto the lens. This way I don't have to worry about other materials giving out under certain conditions.
I didn't want to fiberglass them then something happen and the fiberglass cracks or breaks and the tubes fall out. Glue just didn't seem like a good idea, and epoxy... I was too lazy to go find some.
The first tube I did with a soldering station and a regular tip on the iron. I read that I needed something that would reach 360*C to melt the plastic together, and the soldering station was adjustable to a pretty high temperature, so I used it.
The rest have been done with a butane soldering iron and a knife tip. It's much easier to move around and use it as I don't have a cord stopping me.
The surface came out pretty rough, but it's nothing I didn't expect.
After using an exact-o knife to shave down the surface, I got it mostly smooth, then finished mounting the other tubes.
I sanded the whole thing down with 120g to make sure it was as even as possible.
Glazing putty to fill the low spots left over, then 240g, 320g, and 400g sanding.
I sprayed the inside of the lens black to keep any light from shining through the backside.
I also sprayed a light coat on the front to get a good idea how it looks so far.
This is only the right side so far. I wanted to get it done before doing the other to make sure it's what he wanted.
You can see the slight difference in the angle of the outer light. It looks more angled in the pic, but it's not too far off.
Once both side are done, Paul will finish the wiring then the lenses will be painted to match the car and put back on the housings.
