Lightweight headlights etc.

[JarmoL]

I decided to try and make new headlights for my turboed 968. In addition to save some weight and get a "personal" look, it was now possible to install bigger oil cooler in the space previously occupied by the headlight mechanism. I also removed the power steering cooling loop and replaced it with small Mocal unit.
What I have now is 40 row Setrab for oil cooling and 13 Row Mocal for power steering fluid. Here are some pictures:

Oil cooler

Power steering fluid cooler

Headlight bucket

Relays

Overview

Headlights are Hella H7 bi-halogen units. These have both the hi and low beam, lens is 90mm in diameter. Buckets are aluminium and fiberglass, covers are polycarbonate. Supporting structure is very lightweight and made of aluminium. I used mostly stock attaching points so it's possible to go back to original if desired.
Headlights are locked in place with one bolt accessed by removal of brake cooling duct. After that it's easy to slide the bucket out and change the bulb.

Lights turned out quite ok I think but I really want to make those covers curved. I made several attemps already which weren't very succesfull. Will try again using vacuum forming at work.

 

[paulf968]

Jarmo

hi, your photos are not displaying but I found them here: http://jtleivo.kuvat.fi/kuvat/

Nice work, tell us more about your turbo as there are a few guys on here who love that stuff.

 

[JarmoL]

For some reason I can't make the pictures show. []
Btw. those racing pictures are from Eifelrennen last year. Great event!

Paul my engine is built from 951S block so it's not 3 liter turbo.

Phew. Finally got those pics to show..

 

[stevespic]

Hi Jarmol. thats an Intresting Mod to your lights there. Do you think you have saved much weight by removing the standard lights and fitiings these... It looks a little more aggressive now I think []

 

[lali]

JarmoL,

Those look amazing, did you mould the buckets yourself?

The Eifelrennen was brilliant, I was racing the beetle in the 300km and I will be again this September.

Lali

 

[os951]

Jarmo,
Looks really good. Hope i can see You and 968 with new lights next weekend at Ahvenisto track []
BTW where did you bought those Hella units? I have looked for a decent lighting equipment for 944 GTS style nosepanel/bucket combo

Somehow these dual lense motorcycle units are not what i want to use.

 

[os951]

Saw Jarmo's 968 yesterday. His new lights looked very good. Installation was superb, very easy and fast to remove if necessary. Quality Pro-level job again

 

[JarmoL]

Guys, thanks for the kind words. Yes I did the buckets myself. I used pieces of blue styrofoam sheet to form the shape of the bucket and laid the fiberglass over it. When cured I removed to foam. Not very high tech but works for one off products. []
I think I'll need to find a scale and weigh the new lights. It's several kilos for sure as the original stuff weighs a lot.

Olli I'll try to see if I have some records where the light units came from.

 

[Mike_Pollock]

Saw the pictures on Ollis's 951 thread, they really look superb and Olli I like the 944 nosecone too!

 

[JarmoL]

Little update..

Finally I was able to get the lights weighed. New lights and supporting structure weighs 2,3 kg per side. Old ones are 6,9 kg per side. So the total saving is 9,2 kg. I gained additional 2 kg saving by removing the foglights and replacing them with the cooling ducts. So the grand total is 11,2 kg or 24,2 lbs. It doesn't sound that much but hey.. it's the little things that add up! []

Cheers

 

[galwaytt]

Jarmol - they look really good !

Wondering also about the clear lenses on your front indicator's - are they the 993 ones ?

 

[Super_Marv]

Were you at the Nurburgring last Friday (16/09/11) JarmoL?

I think I may have saw your car in a carpark near Adenau bridge. May have some pictures of your car going round too, if it was you!

 

[JarmoL]

Yes Marv that was me. Leaving on Tuesday so I will go drive some more.. []

 

[Super_Marv]

Lucky you! I had to go back home on Saturday [:'(]

If you want the pictures I took of your car going round, send me a personal message through the forum with your email address, and I'll send them to you.

I did have a bit of a look at your car while it was in the carpark - looks superb. The job you did with the headlights is very professional!