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Old 11-15-2008, 05:51 PM   #1
triple_el
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Default pop-up headlight mod

I have a '93 SC2, and the headlight covers are really beat up (dented/rusty) I was originally going to replace them, but I was thinking... I don't really like the pop-up headlights anyway. So while I was scouring the forums for alternatives, I came across this image:



I know that's a probe converted from pop-up to fixed-position headlights, but I'm not looking for a "how-to", I'm looking for advice.

I want to make a cover like that for my SC2 headlights. My dad** thinks I should be able to use a flat sheet (since the covers are essentially flat anyway) of tempered glass, plexi, or what-have-you... My question is whether or not I need a full enclosure... I don't know much about headlights, but I believe you can buy small sealed projector bulbs, so I wouldn't need to build a reflector for my cover. So I would essentially be removing the pop-up bracket and cover, and attaching a clear cover in the place of the stock covers. Then, I would make a bracket for the sealed bulbs and not care that water can leak around the sides of the cover. That would be my first choice.

Otherwise, I'm thinking that I'll have to make a fully-enclosed headlight assembly, which would be much more involved.

I haven't looked at the wiring harness yet, but I assume it won't be too difficult... I have a manual and my brother is an electrical engineer. I'm more concerned with the mechanical aspect of this project.

Anyone care to weigh in on this? I'm pretty much looking for bulb recommendations, logistical advice, and ideas on how I could attach my cover to the car sturdily without interfering with the aesthetics of the mod.

**Yes, I am only 17, but please don't hold that against me. I rebuilt this car's engine this summer and have been chipping away at the multiple problems it has. I'm quite determined, I just like bouncing ideas off other people.

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Old 11-15-2008, 08:18 PM   #2
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Default Re: pop-up headlight mod

If you make the glass part of the hood, then I think you should be alright. Make the lights permanent in place and have it so when the hood comes down, the plastic is right over the bulbs.

Heres the issue though. The angle may not be enough where the beam can project out. It may get clipped by the front bumber, since your bulb will almost 2-3in lower than the stock bulb. More investicating would have to be done.

You would have to get projectors also

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Old 11-16-2008, 02:51 PM   #3
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Default Re: pop-up headlight mod

The angle is a big obstacle. Find a way to measure the angle, and you can figure out how much space you have to work with. It's going to be tough. The only car I've seen/heard of that has done this, did it for show, and they didn't have enough room to really do it right. It looked good, but functionally the lights did a lot better at giving a clear view of the powerlines than the road.

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Old 11-16-2008, 09:23 PM   #4
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Default Re: pop-up headlight mod

This kinda shoots down the whole "affix the cover to the hood" idea, but would take care of the angle issue... reference this image:



Below the pop-up headlights, there is a rippled part on the plastic bumper cover. if I cut that out and extended the cover to there, it should provide enough clearance... I plan on installing clear corner lights, too... I would rather not do that, but if it's necessary, it's an option.

Can anyone recommend what kind or even a specific brand/model of headlamp to use for something like this?

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Old 11-16-2008, 10:00 PM   #5
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Default Re: pop-up headlight mod

If the projectors are sealed then couldn't you just attach the plexiglass to the bumper once you cut off that little plastic piece on the bumper? Are the stock flip-up headlights flat on the top, or curved? If they are curved then you have to heat up the plexiglass and bend it into shape.

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Old 11-17-2008, 01:14 AM   #6
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Default Re: pop-up headlight mod

I belive I read that the owner of those headlight mods had access to a vacuum molder.

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Old 11-17-2008, 01:18 AM   #7
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Default Re: pop-up headlight mod

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Originally Posted by coolcat2 View Post
I belive I read that the owner of those headlight mods had access to a vacuum molder.
That's correct, and that would be my friend. He is thinking about making inexpensive molds for 1st gen SC2 owners as a side project, and my 94 SC2 would be a test mule.

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Old 11-17-2008, 03:13 AM   #8
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Default Re: pop-up headlight mod

No more pop-up? I could be very interested!

Last edited by coolcat2; 11-17-2008 at 03:15 AM.. Reason: mispelled

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Old 11-17-2008, 08:02 AM   #9
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Default Re: pop-up headlight mod

Have fun, let me know what happens, I thought about doing it once for a HID conversion, but I think I am just gonna go with what I got.

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Old 11-18-2008, 07:03 PM   #10
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Default Re: pop-up headlight mod

Thanks! I admit, it's going to be a while until I get to this (probably until summer - I don't want to get rid of my pop-ups badly enough to do this in a Minnesota winter) but when I do, I'll try to document it and I'll certainly let you know how it turns out!

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Old 11-18-2008, 11:16 PM   #11
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Default Re: pop-up headlight mod

I'd love a 1G coupe to make into a race-only car, and those pop ups are probably the worst thing about them. I was planning on cutting out right below the light...

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Old 11-19-2008, 08:05 AM   #12
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Default Re: pop-up headlight mod

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I'd love a 1G coupe to make into a race-only car, and those pop ups are probably the worst thing about them. I was planning on cutting out right below the light...
ehh the car looks sexy with them down and like crap when they are up. When its just the parking lights on it looks great. Especially when the car is lowered with rims or something.

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Old 11-21-2008, 12:17 PM   #13
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Default Re: pop-up headlight mod

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ehh the car looks sexy with them down and like crap when they are up. When its just the parking lights on it looks great. Especially when the car is lowered with rims or something.
A friend of mine had a Probe, and he just mounted some good fog lights, and never used his headlights...

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Old 12-02-2010, 09:29 AM   #14
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Default Re: pop-up headlight mod

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Originally Posted by triple_el View Post
Thanks! I admit, it's going to be a while until I get to this (probably until summer - I don't want to get rid of my pop-ups badly enough to do this in a Minnesota winter) but when I do, I'll try to document it and I'll certainly let you know how it turns out!
Did you ever attempt this?

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