Project HID Fogs

[s10cyncrvr]

I wanted a set of foglights for my truck, but couldn't really find anything that I liked, so I decided to try and make a set.

Here is what I’ll be using. Bosch e46 D2S Projectors(3-series BMW). Phillips LVQ-212 Ballast(same I’m using for my headlights)


...and here’s the bulb I’m going with, Phillips 3000k D2S. In order to get them over here, they have to break the insulation on the return wire. They still work fine though, and a little high temp epoxy will fix the insulator.


First thing I did was make a new cut-off shield. I wanted it flat to keep the light as low as possible, so that it will stay under the fog. Cut a new one out of stainless and painted it orange to see if it would add any color to the output. It didn’t, so I later stripped the paint back off.


Here is the new shield in the projector.


Here is the output pic. Factory shield on top, new shield on bottom.


Next step was to build a housing to enclose the projector. I measured out the size and shape I needed and then layed it out on poster board.



Cut it out and test fit it on the projector.


After it looked like it was going to work, I used the template as a mold to lay the fiberglass on.


Wrapped it in aluminum foil to help it peel off from the fiberglass.


After a few layers of fiberglass cloth.


Pulled the template out and roughed it into shape.


Cut out the back of the housing so the projector will slide into it. Drilled mounting holes and finished up the smoothing work



Next was a shroud to make the front of the projector more attractive. I used the conduit connector on the left.


Filed it down to the shape of the inside of the housing.


All finished up.


Cut out a piece of rubber to help seal the gap between the projector and the housing. There will be another seal over this one after it’s all put together.


Wanted to make an adjustment system so that they could easily be adjusted a few degrees after they were mounted. The metal bracket will mount to the truck and the projector can be adjusted by increasing the tension on the springs by tightening the bolts. I later added a fourth bolt that was missing in this picture. The projector only uses 3 bolts from the factory so the 4th one was a little different.

[s10cyncrvr]

Moving on, I needed a clear lense for the housing. My buddy xtreme3411 told me about using one of these blind spot mirrors. It worked excellent.


Took off the aluminum backing.


Sanded the reflective coating off with some 2000 grit paper.


Filed it down to the oval shape I needed and fit it up. This later got epoxyed and sealed to the housing.


Started working on the main bracket to mount everything to. Used some angle iron for the horizontal bracket.


The one side bolts into one of the front bumper bolts. Had to make a few cuts to snake it around the frame.


Got lucky in the fact that there was room to mount the ballast on top the main bracket. Cut out 2 strips for the ballast mount.


Welded those to the main bracket.


Here it is all mounted up and ready to try on the truck.



There is still some finish work to do, but I mounted it on there to see how it’s going to work.





Have a few things left to do before this side is done, then I'll have to repeat everything for the other side. After that, I'll start on the wiring. I'm going to rewire the entire lighting system on the front of the truck. It'll be much more user friendly then the wiring harness I made in the Project Projector thread.

[devilman13xx]

thats bad ass man.... cool shit

[AMcCann]

Thats awesome man!!! How much are all those parts costing you?

[ACE2790]

Hot damn Jeremy..your a pro at this. I soon will be goin HID but not retrofit, only a HID conversion kit so i'll be sure to let everyone know how that goes. Good work!

[s10cyncrvr]

Quote: Originally Posted by AMcCann

Thats awesome man!!! How much are all those parts costing you?

It was $369 for the (2)Projectors, (2)Ballasts, (2)4300k Phillips Bulbs(not used), and (2)Ballast Covers. The 3000k bulbs were from ebay for about $100. Everything else was dollar stuff.

[HofinaterSS]

wow, everything you do is so impressive. I wish projects i did came out as clean and perfect as your stuff. Very nice indeed

[zq8fromhell]

bravo bravo, hands down, extremely nice work

[LowTech]

awsome work

[YELLOW2002S10]

very very nice

[Mr Bravada]

damn, thats hot! i never really thought about making my own housings like that, i would have to go square rather than round, but that was brillant using the mirrors for the outer glass, that cut off looked great though, those shields looked great, i love the way that yellow looks, i think i may have to look into this as the next year rolls up, where on ebay did ya find those, and so the broken insulation wire isn't an issue? i would think that it would be....

lol, i was thinking about these fogs the other day wondering what happened to them, glad to see that they turned out looking as they do

[Mr Bravada]

oh yea and be sure to share with us the wiring harness as i'm getting closer to making mine, i almost have the front end put together... so the day is coming!!

[low-s-dime]

looks cool as shit yo...why are they yellow though?

[MoneyMike]

****in pimp shit there.....

[SHROPIE]

very very nice

[orangesonoma]

i got me some yellow hid's for my fog lights in my blazer...cant wait to put them in!!!

[stuntjester1]

very nice

[s10cyncrvr]

Thanks guys. i havn't had much time to work on it lately, stuff has been going out on my daily left and right, so much of my free time has been spent fixing it.

Quote: Originally Posted by Mr Bravada

where on ebay did ya find those, and so the broken insulation wire isn't an issue? i would think that it would be....

If you do a search on ebay for "D2S 3000k" it should bring up one or two sellers. Make sure they are Phillips though. The actual return wire isn't broken, just the insulator around the wire. For some legal reason they have to break it and make the bulb "damaged merchandise" in order to get it into the country. I never really heard a full explaination on it.

Quote: Originally Posted by Mr Bravada

oh yea and be sure to share with us the wiring harness as i'm getting closer to making mine, i almost have the front end put together... so the day is coming!!

The problem I had before was all the fuses, diodes, and relays were in the harness behind the grill. If something were to go out, I would have had to pull the front grill out. It was just a bad design on my part. I always strive to make my work as factory as possible so I wanted to make everything more accessible.

I got these fuse boxes out of a couple of Luminas from the junkyard. I'll have to redo the bases of them but each side will house 3 relays(low/high/fog), 3 fuses, and diodes for the quad beam. Plus they are nice in the fact that you can run one single wire to supply the entire box with power. In the end it will result in a reduction in wires, easy accessibility and simple diagnosis and replacement, and a much more resistance to water.

Quote: Originally Posted by low-s-dime

looks cool as shit yo...why are they yellow though?

It was always believed that yellow light does better in fog because the shorter wavelength won't reflect as much. Now they say that isn't true, and that white or yellow will provide the same visibility. But people and racing teams have used yellow for years so there has to be some benefit to it, plus it looks cool.

[orangesonoma]

good idea with the extra fuse box!

[Mr Bravada]

yea those fuse boxes are a good, cheap idea, and best of all.... look factory

[4.3Xtreme]

you never cease to amaze me
your work is that of a true craftsman
i cant wait to see how the fogs and headlights look together
your truck is nothing short of cover worthy

[dschoeck]

Dang much props to that, looks good man!

[s10cyncrvr]

Here's a short vid, 56k friendly.

http://s-seriesforum.com/albums/albu...ight01_net.wmv (1.0 MB)

[bmxbang]

man i have to say that is amazing it looks so good to and i know it will look good on the truck and your truck is amazing so clean and not overdone thoughs fog lights will look awsome

[low-s-dime]

Quote: Originally Posted by s10cyncrvr

It was always believed that yellow light does better in fog because the shorter wavelength won't reflect as much. Now they say that isn't true, and that white or yellow will provide the same visibility. But people and racing teams have used yellow for years so there has to be some benefit to it, plus it looks cool.

o i know that, i meant how did u find a yellow hid bulb lol...never seen one before

[DNGRS DME]

Wow!

That is amazing!!

Get that thing mounted up and get some pix so we can see what that valence is gunna look like with some fogs in it finally!

[xtreme3411]

Im glad youve got em all figured out. Cant wait to be blinded by em!!!! lol

[Mr Bravada]

that vid was hot man, looks great, keep rollin out the "bright" ideas..... lol

[99 Sdime]

i just bought the same bumper as you and the fog lights that Stylinconcepts.com sold me as" Street Scene" foglights, turned out to be some cheap ones available at advance auto....i didnt want to have to fabricate brackets for the lights, how did u mount the lights onto your bumper..glue?bolt?

[orangesonoma]

Quote: Originally Posted by low-s-dime

o i know that, i meant how did u find a yellow hid bulb lol...never seen one before

i sell them stupid