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Work in Progress: Fog Light Projector Retro-fit - Click HERE for Original Thread

mcmanus7
The previous owner of my car ran the fog lights constantly.. so much so that they burnt the lenses of the fog light housing... so they didn't exactly emit a lot of light due to the damaged lenses.......

I have been somewhat intrigued by the who projector idea... and decided why not try to do a halogen projector retrofit into my old housings... (dealership wanted $90 for one fog light... and these fogs are hard to find at wreckers)...

So first thing I did was pick up a set of fog light projectors... I settled on a set of Blazer brand and picked them up off of ebay... here's what the kit looks like..



It was a pretty good deal... picked them up for $30 it included all the wiring to run fogs (if you don't have factory).. 2 projector housings, 2 894 bulbs and all the mounting hardware....

So on to the retro... Here's a sit by side comparison of the projector to my stock housings.. (not sure why the lens is blue here... it's a perfectly clear lens on the projector)



And here's what 2 hours worth of dremel + drilling has gotten me...



I used a 2 inch hole saw to get the perfect size cut out on the front portion of the lens.... then I basically used a dremel to cut out the back portion until the projector fit into the housing... i'll be painting the outside housing to match the vehicle.. and siliconing it in (even though its a tight fit already)...

Here is what the cut off looks like (with halogen bulb)



Questions and comments welcomed....

STiPWR
Nice work, alot of the times the most tedious small improvements get the best feedback in my experiences.

Anyone can swap out a fog light, but what you did takes time, creativity, and patience, way more gratifying on completion.


Looks good man:thumbup:

mcmanus7
thanks! the light output is 110% better then the old lens.... i'll hopefully have both fully installed by tomorrow afternoon... here's a picture of what the light out put would be if I was to install a hid kit.. the picture is taken from a guy who has the exact same projectors with a 6000k hid set up



BTW that is fog light output only.... not his headlights

Graphicdude
Kick ass job, but I want to see a pic of your car with these bad boys on :D

mcmanus7
unfortunatly as of right now i'll only be running halogens in them.. but if all goes well with this little project i might try a hid kit for the fogs..

ChromeDragon
Holy rock-solid cutoff Batman! Looks great man, how are they on the highway?:dunno:

mcmanus7
unknown.... I am still in the process of getting them to sit 100%

once they are in and aimed i'll be taking them for a good night cruise...


The real pain in the ass thing.. is the mechanism the factory fogs use to aim the fog light is basically a screw that has a spring on it... but due to the how big the projector is.. I've had to be very carefull how much around that area i've cut out... i'll definitely post up pictures once they done....

The best part really is that once they're installed it's just plug and play... the projectors are made for a 800 series bulb which is what my stock set up already is..

Graphicdude
What are you installing these into? What's your ride?

mcmanus7
it's a sunfire gt...

I know I know not everybodies cup of tea... however i'm stuck with it for a few more years... once i'm done university etc...

The fog lights needed to be replaced due to the centers being burnt... the previous owner left the fogs on constantly... these fogs are hard to find at pick n pull and dealerships want 80-90 a peice... so 30 bucks for a set of projectors off ebay and a solid afternoon/a bit of dremeling...

Graphicdude
so your mounting them in the stock fog light area? I didn't know they were that big on the Sunfires.

And honestly, Sunfire or not, still a cool mod :D

mcmanus7
ya the stock fogs for a sunfire are 4".. the projectors are only 2" and the stock opening is roughly 5"... so putting a 2" projector into a 5" hole would look pretty stupid haha here's a picture of to show you the idea of how much had to be cut away out of the back.. I know it looks very crude but the projector sits perfectly level and snug in it..

mcmanus7
alright... so after a few hours of work.... here's the final product... they won't be installed until later in the week.. (going on vacation + silicon must dry)





mcmanus7
Here's the last picture before they get installed... looks pretty good I think

Graphicdude
Hell ya they look good........DUH!!! :D

AudiInProgress
I am impressed.

~sanj~
kudo's dude!

Tech2
Nice job!

Your next project should be a retrofit for mr2s.

hawk81923
r u in edmonton

mcmanus7
yes I am in edmonton.... this will probally be the last retro I do...... unless I get ambitious and decide to do my headlights...

Graphicdude
When you posting pics of the car? I want to see them installed.

Tech2
Yeah man, post pics! You could mount those on a bicycle and they'd still be cool. That's one of the neatest projects I've seen, and one you'll get a ton of use and enjoyment out of.

Actually a projector bicycle kit would also be very very cool. Seriously!

bboybean
HELLA COOL :thumbup: I was thinking about doing this but didnt even know where to start.

mcmanus7
thanks for the positive comments guys!! i'll be installing them this week hopefully... I'm waiting on new bulbs... the 894's that came with the kit have right angle connectors which will not work due to the way the stock mounting harness is..... so i'm waiting on a set of 893's ... it's really not that bad of a project to do... this was my first attempt and it worked out fairly well

Graphicdude
Boooooo!!!!! We've been waiting too long for this! You should be banned :D :lol:

mcmanus7
finally got the new fog lights in........ here's some pictures I do realize the cut off is not level however that's something to do with the way the stock bracket is mounted so I cannot change that first a picture of the stockers.. (note the right side of the stock picture is stock bulbs... the left is luminics 880/9007 combo ultra whites.... I've put 893 ultra whites in the projectors...





Graphicdude
Congrats man, looks really awesome!:thumbup:

AudiInProgress
I love it!

ZEguy
Very cool,hard to believe your a sunfire owner.Good work.:thumbup:

uncle ben
looks great. good job man.

mcmanus7
quote:
Originally posted by ZEguy
Very cool,hard to believe your a sunfire owner.Good work.:thumbup:


ya I know.... the only reason I am is because of being a student... high gas prices.... and i got a good deal on the car...... my sunfire gt is probally one of the most expensive ones made..... it sold on the lot for 29,889

Graphicdude
Please tell me you didn't pay that much for it :blink:

mcmanus7
haha no I paid a fraction of that price... I got it for 4,000 which is a good price considering its year... km's.. and options... and overall condition

Graphicdude
haha, good, you had me worried for a second :D




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