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Gypsy's custom headlights build


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#21 KnightOwl

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Posted 09 June 2018 - 11:34 PM

Got tracking info for my lights...sadness...not until the 13th....wont be working on those this weekend...but look out on Fathers Day!!


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2002 Grand Prix GT 

"All we know is...its NOT The Stig, but the Stig's fat American Cousin!"

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#22 KnightOwl

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Posted 13 June 2018 - 02:06 PM

59dc45f42d0ec7de1e3d7a11528a2b34.jpg Heck yeah The lights came a day early and I couldn’t resist a little mock-up to see how they look! I’m gonna have to trim the inside hole for perfect fit but it looks like it has real potential. I also ordered some LED strips to add to the halos for DRL Sent from my iPhone using Tapatalk

2002 Grand Prix GT 

"All we know is...its NOT The Stig, but the Stig's fat American Cousin!"

WhiteRavenSig-S.jpg


#23 KnightOwl

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Posted 20 June 2018 - 01:08 PM

Next quick step...working on a solution to seal the back of the lights. I decided to utilize the original projector housing which reduces the hole size I need to seal

IMG_6326-M.jpg

 

I then used a step drill bit to open both holes to 7/8 inch

IMG_6327-M.jpg

 

With these open to equal size, I intend to use a couple small sections of hose, one inside another, sealed with RTV that allows the wiring to pass through the smallest hose. High beams thru one, low beams thru the other. Or you could plug one entirely and just use one

IMG_6328-M.jpg

 

Now onward to mounting the LED light to the black inner frame!


2002 Grand Prix GT 

"All we know is...its NOT The Stig, but the Stig's fat American Cousin!"

WhiteRavenSig-S.jpg


#24 Imp558

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Posted 20 June 2018 - 02:27 PM

How about a grommet? harbour freight has a kit.

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"If everything seems under control, you're not going fast enough" - Mario Andretti

1996 Buick Regal L67/4T65E-HD swapped - 1995 Buick Regal GS - 1980 Dodge Sno-Commander - 1968 Empi Imp on '67 Pan - 2001 Chevrolet Express 3500  

Her Stuff: 1996 SSEi - 2001 Monte Carlo SS


#25 KnightOwl

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Posted 20 June 2018 - 07:32 PM

A grommet could work on the high beam hole but the projector bucket hole is too deep. But if all the wires could pass out the high beam hole then I could just plug the other one. We shall see!


2002 Grand Prix GT 

"All we know is...its NOT The Stig, but the Stig's fat American Cousin!"

WhiteRavenSig-S.jpg


#26 KnightOwl

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Posted 24 June 2018 - 02:24 PM

I am struggling a bit on the best way to anchor the lights in the plastic rings. The lights have two small set screws on the housing to attach the supplied brackets but they are made for pedestal type mounting. I need some manner of collar,( like maybe a pvc pipe reducer?) that can attach on the back and hold against the plastic rings.

 

UPDATE, I grabbed some 2 inch pvc pipe collars at Home Depot i think I can cut into brackets. A little bandsaw work is in order but we'll see how this goes

 

GypsyEyes-S.jpg


2002 Grand Prix GT 

"All we know is...its NOT The Stig, but the Stig's fat American Cousin!"

WhiteRavenSig-S.jpg


#27 KnightOwl

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Posted 25 June 2018 - 06:58 PM

I have hit another snag that I’m not sure how to resolve. This red wire came out of its plug. I tried to remove the plug to re-attach the wire but the connector broke.6f5cb56cca0e47c42fcb762635bdaa9f.jpg I think the blue plug is a piece that comes with the aftermarket lights and no clue where to get a new pigtail. 8681113502ea3c2a2a4454f9a764ba88.jpg Is there a stock plug on the car I can rob or do I need to start scouring the web for a solution. I am wide open for suggestions. I wanted to keep the stock harness connections on the car in case the lights don’t work well I can easily switch back to stock. Ideas? Sent from my iPhone using Tapatalk

2002 Grand Prix GT 

"All we know is...its NOT The Stig, but the Stig's fat American Cousin!"

WhiteRavenSig-S.jpg


#28 KnightOwl

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Posted 25 June 2018 - 09:55 PM

Thank  goodness for eBay! I picked up a pair of these pigtail adapters and they are on the way! A little soldering will most likely be in order to provide good wire splicing but that I can do!

Pigtail-M.jpg


2002 Grand Prix GT 

"All we know is...its NOT The Stig, but the Stig's fat American Cousin!"

WhiteRavenSig-S.jpg


#29 Imp558

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Posted 26 June 2018 - 12:09 AM

Those pins can be extracted and soldered to.

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"If everything seems under control, you're not going fast enough" - Mario Andretti

1996 Buick Regal L67/4T65E-HD swapped - 1995 Buick Regal GS - 1980 Dodge Sno-Commander - 1968 Empi Imp on '67 Pan - 2001 Chevrolet Express 3500  

Her Stuff: 1996 SSEi - 2001 Monte Carlo SS


#30 KnightOwl

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Posted 26 June 2018 - 02:22 AM

Those pins can be extracted and soldered to.

 

Thats what I tried to do on the original one and it broke :(


2002 Grand Prix GT 

"All we know is...its NOT The Stig, but the Stig's fat American Cousin!"

WhiteRavenSig-S.jpg


#31 Imp558

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Posted 26 June 2018 - 02:57 AM

It may have just been too brittle.


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"If everything seems under control, you're not going fast enough" - Mario Andretti

1996 Buick Regal L67/4T65E-HD swapped - 1995 Buick Regal GS - 1980 Dodge Sno-Commander - 1968 Empi Imp on '67 Pan - 2001 Chevrolet Express 3500  

Her Stuff: 1996 SSEi - 2001 Monte Carlo SS


#32 KnightOwl

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Posted 30 June 2018 - 10:01 PM

Now that I have a soldering iron and most of the other parts I need I hope to get busy on fabricating the first light housing this week. I'm off Monday and Tuesday so we'll see how much progress I make! ;)  :)


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2002 Grand Prix GT 

"All we know is...its NOT The Stig, but the Stig's fat American Cousin!"

WhiteRavenSig-S.jpg


#33 KnightOwl

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Posted 16 July 2018 - 09:31 PM

73924b725d1fc0cda0b32cfdc0e15180.jpg Tried to get back to work on the lights today but I’m struggling with fabricating the mounting brackets. That and it’s 100 degrees in the garage so not exactly ideal conditions. Not very productive today I’ll get there Sent from my iPhone using Tapatalk
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2002 Grand Prix GT 

"All we know is...its NOT The Stig, but the Stig's fat American Cousin!"

WhiteRavenSig-S.jpg





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