DIY: Custom LED Foglights

Hey all, Im not all that well known here (usually on PreludeAustralia.com) but I thought I might share with the :honda: family anyways :D . Also I want to start posting here more anyways.

About 2 months ago I underwent a mission to create some crazy custom foglights. I think the main inscentive for this mod was to have something different, as well as pure interest as to how good the latest technology in LED (light emmitting diodes :blink: ) is. By no means was this mod an attempt to save money on buying JDM fogs, cuz believe me, it wasnt :eek: .

Everything has been purchused from my good buddy's at Taren Point Jaycar (who should friggen sponser my car or something by now!!), except for the stock moulds of which comes with the prelude.

First up was to build three Drivers, to power a total of six 3 watt Luxeon Star Module LED's (4 white, and 2 blue).

http://img133.imageshack.us/img133/759/img0922qk7.jpg

http://img186.imageshack.us/img186/8048/img0923pl3.jpg

Getting there:.......
http://img133.imageshack.us/img133/8672/img0925ja0.jpg

http://img133.imageshack.us/img133/5052/img0927uk2.jpg

Final Product of Driver #1:
http://img80.imageshack.us/img80/2116/img0926bl8.jpg
...yes even the inductor is hand wound.

http://img80.imageshack.us/img80/3573/img0932cw2.jpg

Thank god upon testing they all worked fine.

Stage 2 involved powering up the LED's for an extended period of time to see how hot they got..

Stage 3 comprised of a trip to Jaycar to get a biggg heatsink, as the small heat sinks used previously were nowhere near enough to handle the heat that is produced from the LED's.

note: Luxeon Star Modules have an optical efficiency of at least 85% (when optic lenses are used), and a power efficiency of around 90-95% when appropriate heat sinks are used. The larger heat sink that I have used allowed the small amount of heat to be dissipated over the whole unit, rather than focussed on the LED itself.

BIG MOFO HEATSINK:
http://img80.imageshack.us/img80/1354/img0935bj3.jpg

Stage 4:
I had to cut the heat sink in half so that it could be fitted in both moulds. Then I went ahead with a small angle grinder and hacked out the moulds and fitted the heatsinks in. Next step was mounting the actual LEDs themselves and the collimators (or lenses..) over the top.
http://img187.imageshack.us/img187/1954/img1020nw7.jpg

Shrouds were made to hide the sides of the collimators.
http://img187.imageshack.us/img187/5340/img1019fd6.jpg

LED's were wired and harnesses made.
http://img187.imageshack.us/img187/8306/img1013gc1.jpg

Then a whole heap of wiring to the glovebox (LED drivers mounted at top of glovebox *hidden*). So far its been roughly, 45 metres of wiring :eek:

Wiring setup:
The LED's are wired through a relay on ignition, with a paralleled switch so that for show and meets I dont have to have the key in ignition just to have fogs going. I have wired up two 3way switches so that outer, middle, and centre LED's can be run individually, or two at a time, or all together.

...and just going through that makes me realise I should have really found something else to do to pass time....:teef:

The Final Result:
well I say final because they are up and running, but Im actually intending to Fibreglass the lenses in so that they are completely waterproof, and Mega professional looking.
(and please give me feedback as to whether you like it or not)

http://img187.imageshack.us/img187/7307/img1037vt2.jpg

http://img187.imageshack.us/img187/2743/img1036ps2.jpg

http://img187.imageshack.us/img187/6642/img1038qu5.jpg

http://img187.imageshack.us/img187/3886/img1027ll8.jpg

http://img187.imageshack.us/img187/8536/img1064cf8.jpg

http://img187.imageshack.us/img187/7163/img1060wi9.jpg

Just with the 2x blue LED's on:
http://img187.imageshack.us/img187/2812/img1050mh0.jpg

http://img187.imageshack.us/img187/6118/img1049tr3.jpg

4x white switched on:
http://img187.imageshack.us/img187/3539/img1046qo2.jpg

I know the blue LED's are illegal for use on the road, that is why they are switched individually. For driving purposes, using only the 2x white centre LED's provide more than enough light for use, but 4x white definitely has a mega sexy factor..

Thanks for looking, and for those that read it all! wow :eek:

nice work =) but yea i'd hate to be caught with blue leds

Top work mate very tempted to attempt this.

Well done... Now can you please do one for me :)....

Nice DIY :)
Great lights, but majority of people aren't THAT electronically minded. ;P

i like :)

sweet:cool:
what about approx cost?

hey looks great, is there any chance of you posting the part numbers you used from jaycar?
thanks:)

Hey thanks for the comments, I'll post up some more pictures because I have done a fair bit more since. Umm approximate cost ended up being ~$400 :eek: but thats because if you see my updates I've moulded them in with Fibreglass and Carbon Fibre.. So, I think it was about $320 for all the parts from Jaycar. I will list the catalogue numbers tonight when I have the book on me. The most expensive parts are the actual LED Star Modules, at $30 a pop, so I used six, thats $180 just for LED's. There are definitely other cheaper LED's that can be used from Jaycar though, including ones where you dont need to use the Power Packs that I have above.

Here are some more photos of the fogs on the car before I moulded them in:

http://img409.imageshack.us/img409/6818/img1109fpz3.jpg

http://img409.imageshack.us/img409/7835/img1110fac4.jpg

http://img409.imageshack.us/img409/1047/img1081fcu5.jpg

http://img409.imageshack.us/img409/2307/img1085ftl6.jpg

http://img409.imageshack.us/img409/469/img1086fpj1.jpg

K, and I've got some updated photos to show the fibreglassing and Carbon Fibre laying.. Big thanks to grnLude for providing the CF sheet for me :teef:

The mould was made using Play-doh.. yeh Im serious..
http://i168.photobucket.com/albums/u...s/IMG_1125.jpg

http://i168.photobucket.com/albums/u...s/IMG_1127.jpg

Stocking stretched over so that the fibreglass mat has something to bond to.
http://i168.photobucket.com/albums/u...s/IMG_1129.jpg

Resin applied over stocking.
http://i168.photobucket.com/albums/u...s/IMG_1130.jpg

Fibreglass mat down and 1st layer of resin applied.
http://i168.photobucket.com/albums/u...s/IMG_1131.jpg

Second layer of resin.
http://i168.photobucket.com/albums/u...s/IMG_1132.jpg

After they dried, excess fibreglass was grinded off and then sanded down.
http://i168.photobucket.com/albums/u...s/IMG_1133.jpg

Carbon Fibre material (is an absolute b*tch to work with) was 'glue outlined' and cut to shape.
http://i168.photobucket.com/albums/u...s/IMG_1134.jpg

Resin was then applied over CF sheets and then shaved.

once dry they looked awesome:
http://i168.photobucket.com/albums/u...s/IMG_1139.jpg

http://i168.photobucket.com/albums/u...s/IMG_1141.jpg

Unfortunately when I applied a couple of layers of clear coat the resin turned a little milky for some weird reason, and the CF look isnt as good as it was when they first dried.. So Im in the process of polishing them back (when I have the time).

Quote:

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Originally Posted by Encor3

nice work =) but yea i'd hate to be caught with blue leds

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Yeh the blue LEDs are just for show, I have them wired separately so they dont come on unless I want them to for photoshoots or whatever.

Ive been driving around pretty much all the time with the centre LEDs turned on and had no troubles from the cops at all. I even had a cop look specifically at the LEDs while on and tell me I could go.. I would debate that they are just driving lights, but I think it would only really be a concern if all 4 white LEDs were on.

good work mate :)
now i have a lil project to do b4 uni starts ^.^

wow hadnt seen the updated pics keegz looks sick...

wow. that is realli impressive work. + points for u!

Unique and crazy!
2 rows of 5-8 leds each would've been sweet too.

Quote:

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Originally Posted by Mrkrooz

wow hadnt seen the updated pics keegz looks sick...

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Thanks maaaang. NSW DIY crew represent!

Quote:

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Originally Posted by Sensei

Unique and crazy!
2 rows of 5-8 leds each would've been sweet too.

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Haha I'd commend anyone that would be willing to dish out the money for that, plus spending the time to build another 3-5 power supply units :p
But yes it would be dam impressive.. and blinding.

Quote:

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Originally Posted by solitz

good work mate :)
now i have a lil project to do b4 uni starts ^.^

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Im glad Ive inspired ya :D do some research first though to see similar LED products that can be used (ie ones that dont require separate power packs) as this could make it a little easier. I dont wanna be blamned for being this mod being a distraction to ur uni studies lol :p

very impressive mate

farrk that looks sexy haha:thumbsup: :thumbsup: keep up the good diy'ing

wanna make a pair for my EG sedan..:P

great job!! thnx for the tips...

i reckon u should sell these, they good stuff :D

i have to admit that is really good - well done - although not feeling the blue LED - personally would have gone for something lighter - but props to you mate

looks awsome

man thats awesome!
couple questions, 1. how much did all the electronics set you back? 2. Do you have a photo of your switch install?

Thanks mate, k from memory the electrical parts including wiring, wiring harnesses, LED's, collimators, LED drivers, heat sinks and switches ended up being about $320. There are definitely cheaper ways to do it, but these LED's are very bright, and very focussed.

In terms of the switches, I've rearranged them, and am in the process of making another little switchbox. Sorry I dont have a photo, but it will end up looking similar to another one I have made, just with toggle switches not push button and obviously no LED's like in this one:

http://i168.photobucket.com/albums/u...s/IMG_1392.jpg

Jaycar sell the little boxes like above, and a variety of switches.

Any Updates?

Either speak to your guys at taren point jaycar or call their headoffice in silverwater on (02) 97418555 in regards to sponsoring (just ask to speak with marketing department)... keep pushing the issue, tell them you'll advertise with stickers and stuff. they might do it, goodluck

Quote:

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Originally Posted by Bayani

Any Updates?

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Its been a while since Ive done anything with them. Ive been busy with a bi xenon projector retrofit with HID, which looks really good with the fogs.

I want to basically buff up the carbon fibre on the fogs to get them to shine like before. I used clear coat and it didnt turn out as good.

Quote:

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Originally Posted by 5thGen

Its been a while since Ive done anything with them. Ive been busy with a bi xenon projector retrofit with HID, which looks really good with the fogs.

I want to basically buff up the carbon fibre on the fogs to get them to shine like before. I used clear coat and it didnt turn out as good.

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Mind if I ask what projectors you're using. :)
& Are you making your own relays for the retro?

Details on HID Retro plz.

Ive used BMW E46 Bi Xenons from a 2004 M3. Ballasts, bulbs, ignitors also from the same M3

Here are a few pics.. Im taking them apart in a couple of weeks to lay carbon fibre on the inside.


http://i168.photobucket.com/albums/u...st07-015-1.jpg

http://i168.photobucket.com/albums/u...st07-014-1.jpg

http://i168.photobucket.com/albums/u...st07-009-1.jpg

By the way, CoZZm0 are you a member on HIDPlanet?

dude, ive done some pretty crazy mods in my time, but the HID conversion has to blow mine out of the water!

i congradulate you on your efforts! very nice work dude...

Quote:

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Originally Posted by EUR003act

dude, ive done some pretty crazy mods in my time, but the HID conversion has to blow mine out of the water!

i congradulate you on your efforts! very nice work dude...

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Thanks mate, it was definitely the hardest and most time consuming project I have done so far, but by far the most rewarding..

I just checked out ur DIY console mod, great write-up! Looks really good :thumbsup:

really nice, id buy this off you..if you made more.
lol

Wow, the headlights look so oool... OMG im still spinning out... Man.... Speechless.... Nice work.... Can you design some clear lights or something different for my euro... I want different tail lights???
PLease!!!

Both the fogs and the retrofit headlights look really awesome, great job.. Makes it worthwhile knowing you didn't just settle for whatever and went for custom, I appreciate that.

I dig the switch to select which lights you have on, good idea, great write up!

hey wat sort of resin did u use to stick the fibreglass down and wat resin did u use on top of the fibreglass to make it glossy?