Well I've been meaning to do this mod for a long time now. As most of you here would agree, one of the problems with the Fiero is that the headlights don't match the sleek lines of the car. Not sure why they couldn't have come up with something that matched the car better but that's the way it is. I've been holding off for awhile hoping that maybe somebody might come up with a kit but that didn't happen. And after I tried my hand at doing this mod, I understood why.
There are a few on this forum who have done a pretty good job. I know of Fieroking's mod on some angel eyes type lights which are nice. I also really like Yellowstone's mod and hence used his as inspiration. They look like they just belong on the car. The mod that I did here were for the same lights (90 mm modules from Susquehanna Motorsports) found here: http://www.rallylights.com/hella/90mm_modules.asp
Here is a picture of Yellowstone's buckets which was my starting point
One of the things I didn't like about it however, was the inward curvatures of the sides. The problem with this is that when the lights are up, you would be able to see through the sides and as a result see the back of the lights. In other words, there is a gaping hole. I wondered why the fabricater made them that way but I soon realized why. More on that later.
My goal was to create something in a one-piece (hehe). And to keep the welding to a minimum as I had no experience in it. So after taking some measurements and drawing up a diagram (which obviously took most of the time for this mod), I traced it onto some sheet metal and cut it out:
Looks simple doesn't it? And then after some bends (I don't have the proper metal bending equipment so a handrail had to do) we have something like this:
Trial fit:
Now we need a piece to make up for this bottom piece which prevents one from seeing into the front of the car:
This was simple enough:
Now we weld the bottom piece to the main piece. Note that this is my first time welding. I know it's a sucky job so let's keep the laughter to a minimum shall we:
To Be Continued...........
[This message has been edited by Suufmeister (edited 10-27-2006).]
IP: Logged
07:48 PM
PFF
System Bot
texasfiero Member
Posts: 4674 From: Houston, TX USA Registered: Jun 2003
The next thing that had to be fabricated was a pair of brackets to hold the headlight motor arm. If that's what it's called. You know the thing that makes the lights go up and down. This is a picture with the brackets welded on and also I cut out the holes to accomadate the lights:
Now came the headaches. Making new buckets is easy. Making sure they clear the pop-up door hardware, is not so easy. And there-in lies all the issues. Now I understand why Yellowstone's buckets were curved inward. So they don't interfere with the hardware. So from here I had to pull out the dremel tool and start making modifications to the buckets I made as well as make some notches in the pop-up door hardware so it clears the bucket when it goes up and down:
Once everything was squared away, I wanted to take the buckets to a metal shop and have them make a pair using all their high-tech metal working gadgetry. Mine aren't bad but nowhere near the quality I wanted. The shop could make nice bends and cut nice holes. Here they are with a coat of paint on them. Later on I'll probably have them powder coated:
Here is a comparison with the buckets I made:
Continued.........
IP: Logged
08:35 PM
Suufmeister Member
Posts: 155 From: Kennesaw, GA Registered: Feb 2005
So now I break out the lights themselves and mount them onto the buckets. This was not as easy as it should be thanks to poor directions from the manufacturer. So it took a little longer then I thought. The wiring of the stock headlights was very easy. The tan wire is the low beam and the other one (I forgot what color it was) is the high beam. Simple enough. Here are the lights/buckets installed:
IP: Logged
08:46 PM
Suufmeister Member
Posts: 155 From: Kennesaw, GA Registered: Feb 2005
Yup. Finally done. There are still some things I'm not happy with but there's nothing I can do about that now. I made notes for the next set though. But that'll be way down the line sometime.
IP: Logged
09:19 PM
cliffw Member
Posts: 37689 From: Bandera, Texas, USA Registered: Jun 2003
Those of you coming down to the Augusta Meet ( Link here: https://www.fiero.nl/forum/Forum1/HTML/060858.html ) will see this mod up close. Should be loads of funs so those of you close by come on down and hang out with us.
Great. I think they are even better than mine because, as you stated, the back of the Hellas is visible when the popups are up. I have to fix that but haven't had the time yet.
IP: Logged
04:02 PM
thismanyfieros Member
Posts: 3468 From: Red Deer, alberta,canada Registered: Dec 2002
I must say, this mod looks even better in person. Great Job Dude!
We had the opportunity to take a closer look at it today at the Augusta get-together. There was a good turnout on a great day--sunny skies and just-right temps. (Thanks again for pulling that together, guys, we had a great time.)
Here are some pics that give a bit more info for comparison purposes......
Side-by-side with a "stock" headlight assembly on my '86SE..
A closer look....
Gettin' down an' dirty....(guess this mod means you won't get quite as many bugs on your headlights)
Now for the measurements....before (about 5 1/4"+)
And after.....(about 3 1/4")
This is very classy and exotic-looking and adds just the right touch to the car's overall look. You do know, of course, that I'll be comin' over to get help with installing these babies on my car next? LOL (I'll spring for the Hooters wings. hehe)
Great job again man. You never cease to amaze me with the details on your car.
Keep up the good work.
~Tress
IP: Logged
08:57 PM
alex de jorge Member
Posts: 501 From: Kissimmee, FL Registered: Nov 2005
Awesome. If you're going to have pop-ups, that's the way to go. I like pop-up headlights, but the motors & gears go bad, and a nut can easily be overtightened when you work on 'em. So I'm going to flushmounts as soon as I can. But I really like what I see here.
Thanks everyone for the compliments. I've had many messages asking if I will make these available and if so what would be the cost. I guess I should've expected this so I will address this issue now...
These buckets are NOT plug and play. If you recall from the pic above, I've had to make modifications to the pop-up door hardware so they would clear the buckets. Basically I got out the Dremmel tool and started cutting and grinding until all the clearance issues were resolved. By the end, I couldn't even remember what it used to look like. So there is no way for me to explain where and how much cutting that needs to be done. Not only that, but if I sold these that would just be wrong. I wouldn't want anyone here to have to hack up their pop-doors to make these fit right.
I've spent about two months working on this mod and learned some things that will hopefully prove usefull for the next set I make. I'll explain...As I stated, the clearance issues mainly occur with the brackets on the sides that attach to the sub-assembly. Here is the picture again:
What I will do is cut the side brackets off. Then fabricate a couple of brackets to be welded about an inch and a half outside the two brackets in the middle which is where the motor arm bolts up. These two brackets will Y-out and attach to the sub-assembly. In addition, I will modify the sides slightly so the curvature is more in-line with the curvature of the pop-door hardware. Of course in order to do this I'll need to scrounge up another set of pop-up doors somewhere to put on my car to make sure this new set will be plug and play on any Fiero.
So this is where I am with it. I know there are a few out there that would like to have these buckets. I mean the stock headlights are just not sexy as most of us would agree. Once the adjustments are made and I am satisfied that they would bolt right up on any Fiero, only then will I think about making them for others. Those of you that know me know that I only accept high quality. I would never sell something to somebody else if I wouldn't put it on my own car.
The next question I may recieve is when it might be done. Well as I stated I spent two months on this mod which is longer then I wanted to spend on it. And I don't have the time to dedicate to it in the immediate future. Especially with the holidays around the corner. So more then likely it will be after the holidays.
One thing to note is that these buckets were specifically made for the 90mm modules ($58.75 each). However I would imagine they would work for other headlights as well. Instead of cutting holes for the 90s, you'd just have to cut holes for whatever headlights you intend to use. Although how it will look will depend on what was used obviously.
Very nicely done and I totaly understand your desire for a perfect product. Should you get to the point that you are going to sell these let me know and I will definately be in line for them. Again, great craftmanship!
Nolan
IP: Logged
03:51 PM
Suufmeister Member
Posts: 155 From: Kennesaw, GA Registered: Feb 2005
Just to let everyone know...there is someone currently developing headlight buckets that will be a direct bolt-on. I won't give out too much information cause I'm sure he'll be able to provide a better discription when he is ready to make them available. He is in the final stages of R&D now so they aren't too far off.
IP: Logged
04:47 PM
PFF
System Bot
thismanyfieros Member
Posts: 3468 From: Red Deer, alberta,canada Registered: Dec 2002
I almost have the bracket R&D finished!! I hope to have them ready by December. I will be offering 3 styles. The twin 90mm rounds, 90mm high Rectangles and a blank face for those with their own light combos.
of this kind of mod, I think this is the best one i've seen yet, but in my opinion, I think that they open up a little too small. I think I would personally prefer something in between what you did and stock, but that is just me. good job.
IP: Logged
01:08 AM
swisscheese Member
Posts: 537 From: somewhere over the pond Registered: Oct 2005
(I'll spring for the Hooters wings. hehe)
)
