Tuned Headlights

[SwankBaton]

The recent thread on HID's inspired me to have a look at the Hella 90mm Low beam projectors.

Started to dismantle, the reflector bowl and lense are tiny ! Here they are next to a Hella 'E55' Bixenon :




See the damage on the bowl ? Probably moisture , some baked on marks as well - I dont think these will hold up well with a true 55w HID, I'll be sticking with 35W

Here is the standard cut-off shield - This is designed for a halogen bulb :




Set about creating a new shield , here it is before cleaning up :




First attempt :



Notice anything wrong with the step ? Its LHD ! - No worries, just flip the shield over.

Curved the shield and lowered it a little to get more light through beneath the step (otherwise its wasted) :


Now looks like this :



Nice bit of color at the cut-off, left hand side looks sharp and straight, right hand side needs a tweak on the curvature of the shield to achieve the same.

Thats focused about 8 to 10 feet away from me so I'll be off to find a large flat wall and re-focus at 25ft. I will have a look at spacing the projector lense with washers to get a nice blue cut-off all the way along the beam.



Does anyone have access to a laser cutter ? Would be nice to able to re-produce the shields.