Progress sounds awesome so far and looking forward to the finished product. A few questions to clarify a few things though (pardon my innocence):
1. The full kit comes, as you say, comes with the front covers. Are these the GTS clear covers you were referring too?
2. I assume the reason why you're using the H9's is because those ARE DOT approved whereas the H7's aren't. What kind of beam differences are there between the H7's and the H9's though? Is one type brighter than another? Whiter white? Etc....
Bolt-In, Plug-and-Play Projector Lights
1. No, the "cover" referred to as part of the kit is not the GTS headlight cover - it is just the outer part of the housing, similar in appearance to the Ford Focus projector units.
These can either be painted or "chromed" (you must do one or the other, even if you are just painting them matte black), and the GTS headlight covers (NOT included) can be used over top of them if you prefer the look with an outer "lens".
2. There are two reasons for using the H9 lights in the kit - cost and DOT compliance. The H9's cost a little more than half of what the H7's cost, and being DOT-compliant, they are legal for road use in the USA.
As far as I am aware, there is no difference in the high-beam pattern, while the low-beam may not have the same sharp horizontal cut-off across its beam as the ECE-spec H7 because the DOT requires more light higher up at the centre of the beam pattern to illuminate overhead signs. If that is the case, they may annoy oncoming drivers more than the ECE lights, but should put the same amount of light on the road. Once I have the kit working, I will take some beam pictures.
The H9 units have the same output (in lumens) as the H7's at the same wattage (the standard H9 bulbs are 65W), with a slightly higher colour temp (3430 K vs. 3000 K for the H7's), meaning the light would be perceived as "whiter".
These can either be painted or "chromed" (you must do one or the other, even if you are just painting them matte black), and the GTS headlight covers (NOT included) can be used over top of them if you prefer the look with an outer "lens".
2. There are two reasons for using the H9 lights in the kit - cost and DOT compliance. The H9's cost a little more than half of what the H7's cost, and being DOT-compliant, they are legal for road use in the USA.
As far as I am aware, there is no difference in the high-beam pattern, while the low-beam may not have the same sharp horizontal cut-off across its beam as the ECE-spec H7 because the DOT requires more light higher up at the centre of the beam pattern to illuminate overhead signs. If that is the case, they may annoy oncoming drivers more than the ECE lights, but should put the same amount of light on the road. Once I have the kit working, I will take some beam pictures.
The H9 units have the same output (in lumens) as the H7's at the same wattage (the standard H9 bulbs are 65W), with a slightly higher colour temp (3430 K vs. 3000 K for the H7's), meaning the light would be perceived as "whiter".
Ohhhh!!! I see now. That makes a lot more sense now cuz I was wondering how the chrome would be possibly be damaged by rock chipping as you mentioned even though front covers were supplied. You just meant that black top covering on top of the lights themselves. 
Well, now that I understand that a little better, even without the chrome plating on the housings, it would stand to reason to be a prudent idea to have that outer "lens", as you put it, in order to keep the lights from being damaged by rock chipping as well, would it not?? So are we just supposed to bake the stock lights and take the lens cover off that and clip that onto the new housings??
For that matter, if I wanted to go with a clear type lens rather than how "lined" the stock lenses are, where do I get a set of those GTS covers?
Well, now that I understand that a little better, even without the chrome plating on the housings, it would stand to reason to be a prudent idea to have that outer "lens", as you put it, in order to keep the lights from being damaged by rock chipping as well, would it not?? So are we just supposed to bake the stock lights and take the lens cover off that and clip that onto the new housings??
For that matter, if I wanted to go with a clear type lens rather than how "lined" the stock lenses are, where do I get a set of those GTS covers?
What I drive: A Cybertronian disguised in the form of a Creek Blue Mica 95 MX-3 GS. 
Long term goal: Fabricating a new transformation cog!
Long term goal: Fabricating a new transformation cog!
The Hella light units are designed to be used with no other external protection - they are used with no external "lens" on Hella-produced kits for the Focus, VW Golf, etc. I know several people who have had these kits on Golfs with no breakage issues - they are no more susceptible to breakage than a stock headlight. The only reason to fit the GTS headlight covers is aesthetic (I.E. if you prefer the look with the external "lens").
The lenses from stock MX-3 headlights WILL NOT FIT the housings I am producing. Your only options if you want an external "lens" are the GTS covers (or similar commercially available ones) or custom fabricated ones. Lots of auto parts stores carry the GTS products, or you can go to GT Styling's website.
The lenses from stock MX-3 headlights WILL NOT FIT the housings I am producing. Your only options if you want an external "lens" are the GTS covers (or similar commercially available ones) or custom fabricated ones. Lots of auto parts stores carry the GTS products, or you can go to GT Styling's website.
Okay - another update:
I will have the latest prototype mounting brackets back from my plastics guy late this week.
The material for the mounting bracket has changed - it is not black ABS plastic anymore, it is clear polycarbonate, which is a more dense, stronger material. The fact that it's clear - well, that's just because that is how it is most readily available. If you don't like it, you can paint it, but most of the time you won't see it anyway, and I'm sure some people will like the fact you can see through them...
Due to the extended prototyping stage for the mounting brackets, we are now looking at early to mid-November, possibly December before we will have kits ready to ship. The lead time to design the housings and create the moulds is about 4 - 6 weeks. Sorry for the delay, but I'm managing this project in my spare time, and I don't want to rush these out and give you a crap product!
I will have the latest prototype mounting brackets back from my plastics guy late this week.
The material for the mounting bracket has changed - it is not black ABS plastic anymore, it is clear polycarbonate, which is a more dense, stronger material. The fact that it's clear - well, that's just because that is how it is most readily available. If you don't like it, you can paint it, but most of the time you won't see it anyway, and I'm sure some people will like the fact you can see through them...
Due to the extended prototyping stage for the mounting brackets, we are now looking at early to mid-November, possibly December before we will have kits ready to ship. The lead time to design the housings and create the moulds is about 4 - 6 weeks. Sorry for the delay, but I'm managing this project in my spare time, and I don't want to rush these out and give you a crap product!
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projectmx
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uhm is there still no mok-up of what they might look like?
ProjectMx
My BP and AWD build thread
Cardomain
93 Mx-3 GS with bp and GTR AWD system
93 Escort GT daily driving
My BP and AWD build thread
Cardomain
93 Mx-3 GS with bp and GTR AWD system
93 Escort GT daily driving
So far, no. The external housings are being designed and prototyped in AutoCAD, so there is no physical prototype for those. The previous mounting brackets, quite frankly, looked like crap, so I didn't want to post pics of those.
I WILL take some pictures of the light units mounted in the mounting brackets when I get them back later this week - that will at least give everyone an idea of the positioning of the light units, the clearances, and a rough idea of the overall look. Hopefully all the various bits and pieces to make the wiring harness will have arrived by then, so I can give you some beam pattern shots as well.
I WILL take some pictures of the light units mounted in the mounting brackets when I get them back later this week - that will at least give everyone an idea of the positioning of the light units, the clearances, and a rough idea of the overall look. Hopefully all the various bits and pieces to make the wiring harness will have arrived by then, so I can give you some beam pattern shots as well.
That is a possibility, as I have said before, but until we have confirmed the fitment of the mounting bracket and worked out how it will interface with the housing, we don't have a final design to show.
Regardless, I don't think it will give you any more of an idea of the eventual look than the pictures of the Ford Focus lights I have referred to several times in the past. Without actually seeing the housings on the car, it is hard to see how it will REALLY look...
That said, once we are nearer to having the final CAD design done, I will post what screenshots I can.
Regardless, I don't think it will give you any more of an idea of the eventual look than the pictures of the Ford Focus lights I have referred to several times in the past. Without actually seeing the housings on the car, it is hard to see how it will REALLY look...
That said, once we are nearer to having the final CAD design done, I will post what screenshots I can.
As mentioned a few posts above, we are now looking at mid-November to early December for production to begin.
As for when images will be posted - well, I should know tomorrow whether my mounting brackets will be done on schedule. If they are, I will post the images of the light units mounted on the weekend.
After the design of the mounting brackets is finalised, I would think that we could have a CAD screenshot at the very least within two weeks.
As for when images will be posted - well, I should know tomorrow whether my mounting brackets will be done on schedule. If they are, I will post the images of the light units mounted on the weekend.
After the design of the mounting brackets is finalised, I would think that we could have a CAD screenshot at the very least within two weeks.
They are not "angel eyes" - the light units the housings are made to fit do not have the lighted surround that "angel eyes" have. The housings will fit any Hella 90mm high or low beam light unit, including the H9 and H7 halogens and the D2S Xenon's. Note that this does not include the Bi-Xenon's - they have a different design that is not compatible.
My prototype brackets will apparently not be delivered until next week, as I have not heard from my plastics guy today, so no pictures until next week. Sorry folks!
My prototype brackets will apparently not be delivered until next week, as I have not heard from my plastics guy today, so no pictures until next week. Sorry folks!