DIY KnightSports Carbon Fiber Dual Head Light Kit
 

Ok here's the skinny, I just recently picked up an authentic set of Knight Sports Head lights. I was going to install them, but anybody whose has them or seen them the shrouds are made of thin fiberglass. Well long story short I love the look of these lights & would be pissed if somebody were to hit my car (Knock on wood) & i'm out a set of $1700 lights!

So i have decided to replicate my knight Sports headlight kit to have a backup set on hand & to possibly sell a limited number to the community to make there own kit.
I intend on reproducing only the head light shrouds & headlight mounting brackets.

These will be EXACT replicas of the original Knight sports Head Light Kits with the exception of lighting.

The only Revisions to the light kit will be: (Carbon Headlight Shrouds)

Now as I said before I'm reproducing an extra set for me as insurance, & would gladly offer the community the opportunity to buy these replicas. Of Course you would have to source your own lights but by doing so you'll save yourself a couple hundred dollars off an original Kit :nod:!

Please chime in and let me know what you think.

Thanks for lookin,
Idel
Heres a pic of what they look like if your unfamiliar with them (Pic courtesy of Link).

http://i895.photobucket.com/albums/a...K_KSLIGHTS.jpg

& heres the pic's of my set:
http://i895.photobucket.com/albums/a...s/DSC04721.jpg

http://i895.photobucket.com/albums/a...s/DSC04722.jpg

http://i895.photobucket.com/albums/a...s/DSC04724.jpg

wow thats awesome work and a great idea. how much would a set cost? You will be a very busy person b/c im sure there will be tons of interest!

^
Well actually I wont being doing too much work because I found a company that specializes in building carbon parts for race cars & bikes to do the shrouds. The hard part is finding someone willing to fabricate a limited number of brackets (for a reasonable price).

As far as price is concerned I'm still working out the details but i expect it to be less than the Knight Sports Halogen kit that sells for $775.

You will definitely see a lot of interest as long as fitment is good. I get an e-mail at least every other week requesting a set of these.

^
Bryan, I remember you saying how hard these were to get & I absolutely love the pop up lights so I had to jump on it!

Idel

im interested

damnit now im curious your local pm me i want to have a few words with you

do it...do it yesterday...

Long as fitment is good I'd def be in...

I still don't understand what the big fuss is over these lights. The output on them is horrible, Knightsports stopped making them for a reason.

Light output can be changed. They keep the sleekness of the pop-up lights when they are down and don't look god awful when they are up like the stockers. I personally would not go any other way then this if keeping the pop-ups. Just my .02

I agree with Bryan I love the look, as far as light output is concerned I ain't sure yet cause I haven't hooked up the IPF's yet. So I if sell a couple kits they would be without lights so the customer do there own thing, fitment MUST be spot on if not I'd never put them on my car let alone sell them.

If you can make this work then i might choose this option over the EVO-R kit from RX7store.com

^
On sunday I'm gonna talk to a reputable forum member about fabbing up the brackets. This is my biggest hurdle at the moment. ;)

How about something similar, but more updated?

https://www.rx7club.com/attachment.p...1&d=1275885478

https://www.rx7club.com/potential-advertisers-223/fd-sleepy-eye-hid-conversion-879394/

Looks like the body shop will offer the shrouds in FG or in CF and will also offer a kit.

^ Very nice David i'd definatly Rock those but I'm not a baller like you lol, so i'm stuck with my knightsports. Like bryan said earlier I love the look of the pop up lights & the dual bulb setup IMO makes the FD look exotic like a Lotus or something?

I see no problem with lighting as I have the KS HID kit. However I wouldn't pay 775$ for a backup pair of shrouds.... I already have everything else..

Then would you be kind enough to post some pictures of the light output against a wall from roughly 25-30 feet away?

-Dan

I didn't say anything about $775 for a backup pair of shrouds, I did say I expect the kit which will be of better quality than the original (mainly the shrouds) to be cheaper in price than the original KS Halogen kit so the customer can source their own lighting.
Also the shrouds will be made available to those who already own a set of KS.

Idel

Only pics I have of light output I pointed them down as I didn't want to blind people ahead of me. However as you can see they can go much further and shoot out alot more light if I wanted to.
http://www3.telus.net/public/a5a21790/rx-7/DSC00762.JPG
http://www3.telus.net/public/a5a21790/rx-7/DSC00761.JPG

No cutoff right? That's the problem with the KS kit - you don't have proper lighting and will blind oncoming traffic.

Proper cutoff and the result at night:

https://www.rx7club.com/attachment.p...1&d=1276258173

https://www.rx7club.com/attachment.p...1&d=1276258173

Odd looking cutoff you have there David. Maybe the lights are not adjusted quite right?

Correct, the left light needed to be raised up. I have done this but don't have new pics.

The euro cutoff is different than the US one - it has a sharp distinctive line across the top as opposed to a less severe rounded cutoff in the States. Here is a good example of a properly aimed US cutoff from a 2006 BMW M3:

https://www.rx7club.com/attachment.p...1&d=1276260004

See the SakeBomb kit for an example of a euro style cutoff. The upside to the euro design is less light at the oncoming traffic. The downside is less lighting available to the driver when going up and down hills and the severe cutoff line can take time to get adjusted to as you notice when you hit bumps.

^
David is the inner bulb housing the same size as the Knightsports
IPF?

Idel

Yes, the KS kit uses two 90mm units. I used one 90mm unit and then a 50mm unit for the outside. You could retrofit any of the hella 90mm units into your shroud and have balling lights with proper cutoff.

Here are the 90mm units:

http://www.rallylights.com/SearchRes...CategoryID=568

They offer the units in both ECE (euro) and SAE (US) models. As a low cost entry, the Hella Bi-Halogen 90mm Hi-Lo Headlamp is a great option for you. It would give great light on both low and high beam and you could have four lights on on high beam which would be crazy bright. Rallylights says four beams on during low beam is against the law in most states - not sure in Europe.

If money is no object, then go with:

http://www.rallylights.com/detail.aspx?ID=4283

Those would be crazy bright and you would combine them with a halogen high beam.

There are other alternatives also and all of the Hella units are ECE or SAE legal meaning they have been tested and approved for headlight use.