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Old 03-23-2006, 09:22 PM   #1 (permalink)
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How To: VW Golf Projector Headlights

This write up well make your normal NX headlights into projectors which will look like this when its done:



Well after coming across a picture posted by Pretty White of this done by someone else, I decided I had big enough balls to try it myself. And as long as you can live with a slight gap and your not scared of cutting on your car a bit, then read on.

My friend Zac (niSE7EN) and I did this in about three hours.

What you need:
MK3 92-98 VW Golf Projector Headlamps (You can get them off ebay, either black or chrome housing your choice):
Example:


Reciprocating Saw <-------A must
Wire cutters\strippers
Drill
Self Tapping Sheet metal screws
washers
2 Small Angle Brackets
Soldering Iron
Solder
Flux
Matching or close to matching spray paint


First thing you need to do is remove the front bumper you can find this procedure here:

http://www.sr20forum.com/nx2000/79353-how-take-bumper-off.html

Now remove your stock headlights. Move the harnesses to them out of the way.

Next you need to start your first part of cutting the lip under the headlight hole needs to be removed shown here, do this on both sides:

Before:


After:



Your going to have to cut off three out of the four mounting brackets on the VW headlights, the one you want to keep is the top right one on the drivers side and the top left one on the passenger side. Cut them off as smooth as possible.

Now try to put them where the stock headlights go, you will notice the housing of the VW headlights are much larger than the NX. This is where you need to start cutting to make them fit most of your cutting is done on top and on the inside by the radiator, you want to get the headlights since they are so big as far inside as you can (refer to the pictures for that to make sense.) Basically you want to put them onemark where they are hitting, pull them off and cut a little bit, put them back on and try to fit the bumper and repeat. Never take too much off, its better to cut many times and get it than cut once and risk the chance of screwing it up. Repeat this process till you get them fitted as best as possible this it how mine looked after I cut and painted where I cut. Keep and mind they wont fit perfectly.

Drivers side for example:




Once you got them where you want them mount them with the self tapping screws and washers I mounted mine like so:

The bracket on the headlight up top:


The L bracket on the inside:


Now for the wiring:
Cut the stock harness connection ends off the VW headlights
You will notice all the bulbs on the headlight ground to one wire. You want to cut the stock connector off the NX headlight harness its the one that has three wires.
Conect the wires together with a soldering iron, flux and solder.

The harnesses go as follows:
Driver's Side:
VW harness-----------------Car harness
black--------------------------blk w/silver dots
red----------------------------red w/black stripe(high beam wire)
blue---------------------------red w/yellow stripe(low beam wire)

Passenger Side:
VW harness-----------------Car harness:
black--------------------------black w/silver dots
red----------------------------red w/green stripe(high beam wire)
blue---------------------------red w/blue stripe(low beam wire)

Both Sides:
Angel eyes------------------Inside Parking Lamp Harness
red---------------------------red w/blue stripe
black-------------------------black

Outside Turn Signal:
Passenger Side:
VW harness----------------Car harness:
white------------------------green w/yellow stripe (Run Inline)

Drivers Side:
VW harness----------------Car harness:
white------------------------green w/black stripe (Run Inline)

Tape up the wires with electrical tape, mount the headlights and put the front bumper back on. And the headlights should work like this:

Parking Lights (They appear blue but they are white):


Headlights:


Brights:


Turnsignal:


Test everything for correct function and enjoy.
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Last edited by sinistersntra91; 04-15-2009 at 08:20 PM.
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Old 03-23-2006, 09:34 PM   #2 (permalink)
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nice right up man....good stuff :0)
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Old 03-23-2006, 10:04 PM   #3 (permalink)
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They look pretty cool. I would like to see full size pics outside during the day. So I take it each light has a seperate adjuster that you can access from outside the housing to aim them? I ask because the way you have the housing rigidly mounted it wouldn't be adjustable by itself.
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Old 03-23-2006, 10:06 PM   #4 (permalink)
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wow, thanks a lots for this diy !
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Old 03-23-2006, 10:14 PM   #5 (permalink)
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Originally Posted by paNX2K&SE-R
They look pretty cool. I would like to see full size pics outside during the day. So I take it each light has a seperate adjuster that you can access from outside the housing to aim them? I ask because the way you have the housing rigidly mounted it wouldn't be adjustable by itself.
yeah there is some adjusting bolts on the back of each lens for aiming, I have yet to mess with them because the car has yet to leave the garage
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Old 03-23-2006, 10:14 PM   #6 (permalink)
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wow, thanks a lots for this diy !
Not a problem.
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Old 03-23-2006, 10:25 PM   #7 (permalink)
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Someone should sticky this before it gets lost!
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Old 03-23-2006, 10:26 PM   #8 (permalink)
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Thankyou heaps! now i can order a set good lighting here i come!
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Old 03-23-2006, 10:32 PM   #9 (permalink)
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Quote:
Originally Posted by Kickin_Wing
Someone should sticky this before it gets lost!
Oh please believe that when pretty white sees this hes going to Sticky it ASAP.

The only thing that agrivates me is having to cut the cars metal up. There has to be another way...
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Old 03-23-2006, 10:41 PM   #10 (permalink)
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Maybe you could heat it up with a torch and bend it? I don't know how well that would work or how safe it would be, but it's an idea.

EDIT: Now that I take a closer look, I don't think you could bend that. Oh yeah, and before I forget, What is flux?!

Last edited by Kickin_Wing; 03-23-2006 at 10:44 PM.
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Old 03-23-2006, 10:47 PM   #11 (permalink)
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Flux Capacitor DUH! Gaaaaawsh every car in the whole entire world comes with one stock!

But seriously. I just ebayed the headlights and it looks like its going to be about $150 shipped for a set of projectors MK3 lights....and those are the cheap ones.
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Old 03-23-2006, 10:57 PM   #12 (permalink)
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Quote:
Originally Posted by Kickin_Wing
Maybe you could heat it up with a torch and bend it? I don't know how well that would work or how safe it would be, but it's an idea.

EDIT: Now that I take a closer look, I don't think you could bend that. Oh yeah, and before I forget, What is flux?!
Flux or soldering paste, its the stuff you put on the wires to make the solder stick. Really there is no other way, you have to cut it unless you could get some lower profile headlight housings. Its the size and shape of the housing, that makes you have to cut the stuff, but really I dont think you will want to go back to stock once you have these so why not cut some metal to make it fit?

Last edited by sinistersntra91; 03-23-2006 at 10:59 PM.
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Old 03-24-2006, 12:19 AM   #13 (permalink)
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if it isn't the part that aims the lenses, and is just plastic behind the individual housings, can you cut some of that out instead?
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Old 03-24-2006, 12:27 AM   #14 (permalink)
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nice work
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Old 03-24-2006, 12:45 AM   #15 (permalink)
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if it isn't the part that aims the lenses, and is just plastic behind the individual housings, can you cut some of that out instead?
No I looked at it really the only thing you can do with it is cut the area that the nx headlights sit in bigger, the way that headlights are made makes it impossible to really do anything else. The reason being is if you cut into the housing you will loose the seal on the headlights causing moisture to form.
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Old 03-24-2006, 12:53 PM   #16 (permalink)
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I beat Pretty White to making it a sticky!

PS, can you get some pics of the actual gap you speak of? Is it on the top, or bottom of the headlights?
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Old 03-24-2006, 04:07 PM   #17 (permalink)
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looks amazing .. cheers for the write up ..
not sure on which pic Ian posted but one of our members over here on this side of the water did a conversion like this using Bmw twins .. (sorry not sure on model - memory fails me at the moment) looked fantastic but had to removed them due to failing road worthiness test (MOT) Pic is here

superb job .. thumbs up for the write up and all that work
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Old 03-24-2006, 04:45 PM   #18 (permalink)
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This is the only noticable gap the only other one is up top and you have have to either lay on the ground or stick your fingers in there, even this gap is not that noticable, the only reason you see it is because of the flash which I put on intentionally so you can actually see the gap.

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Old 03-24-2006, 04:51 PM   #19 (permalink)
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Thats not too bad. I'm sure it can easily be fixed.
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Old 03-24-2006, 04:55 PM   #20 (permalink)
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Yeah Im really not that worried about it the only reason why the gap is there is because of the headlight it curves in right there
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