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.

^
You are the man, I'm sure the question where to buy? & what to get? was gonna come up sooner or later I think I'm might sell my IPF's & go the ballen route lol.

Thanks again,
Idel

:lol: By people ahead of you did you mean that propane tank? See when you have a proper HID projector setup that is aimed correctly you don't have to worry about blinding other drivers. When I talk to others using these "HID" reflector based kits and mention blinding oncoming traffic or other motorists I often hear "WTF do I care as long as I can see" That's a GREAT mentality to have :icon_tdow
If you could fit a projector based round headlight behind those shrouds that would be perfect.

David, lol seriously dude. How many times to I have to show you what a DOT and ECE cutoff looks like. We use a DOT style cutoff.

-Dan

Don't think so brother. That's ECE all the way for sure :) Sharp cutoff = ECE = SakeBomb retrofits. Smooth cutoff = SAE = David Hayes HIDs

Smooth SAE cuttoff from 2006 BMW M3:

https://www.rx7club.com/attachment.p...0&d=1276260002

Sharp SakeBomb cutoff:

https://i723.photobucket.com/albums/...e/DSC02694.jpg

Notice any difference? Hint: ECE units have sharp well defined angle cutoffs and SAE units have rounded, smoothed out cutoffs.

Don't waste your money on EVO-R crap. See my sig for details. :nod:

Wow you're intent on crapping on this guys thread aren't you. Sorry to hijack your thread dude.

I guess the IS250 also has ECE style cutoff from the factory too huh? :scratch:
Did you ever consider some manufactures use a different beam pattern? Yes ther is more then one SAE beam pattern. Sorry dude not everything you do is the ONLY way. It's ok to be wrong sometimes.

https://s59.photobucket.com/albums/g.../DSC_2802h.jpg
IS250


If you really want to debate the subject do it somewhere else. Again sorry for interrupting your thread MSTHTD1

EDIT: Of what I posted ripping Scrub. Sorry to the OP. No more non thread related posts from me.

No worries everybody like I said before I'm trying to protect my investment by replicating my set. If there's enough interest I'd make a limited amount of kits For those who like the KS kit as Much as I do! Now scrub your kit updates the the look of the fd and is effective, but not my cup of tea. David has a one off kit similar to the KS nice & effective aswell. Long story short it's Mazda's fault they should've addressed the lighting on the FD's long before they hit the showroom floors!
Lmao. Hell if scub can do it, & David could do it then by golly I'll do it to! Lol

Idel

Now that is too funny! Good luck with the effort. There are a lot of good lighting choices available now that would make the KS kit much improved.

Watching.

Fingers crossed.

Mike

FWIW I Just noticed the lights (tail lights & corner markers) on this IS 250. Their not even on :scratch:, the hood is open & the light source seems to be coming from under the hood? hmmm is this your ride with the FD Projector lamps sitting on the re bar? Or Google image?

I was just using that as an example. It was from some dudes thread on the Lexus forum. I can certainly show you more examples if you're really that interested. There is more then one SAE type beam pattern.

Yes you can certainly create your own setup, it's not super difficult just time consuming. Everyone likes their tea a different way ;) so no worries.

No, you said those were factory cutoffs and they clearly are not. Might want to review the pic before you post it to ensure the light is coming from the actual headlights of the car before you post. You might also want to check out the source of that pick, "JVX", and you just might learn he does a ton of retrofit HID stuff, not OEM. He takes halogen projector units and converts them with HID with very good results.

And finally, you might want to check with your partner before you make your claims about SAE lighting:

So who is correct, you with your SAE pattern claims or Heath who says the SakeBomb lights are an ECE (euro) pattern?

You're referencing a single post I made regarding the legality of the SakeBomb Garage headlights. In that post I said in essence "Hey guys I'm not sure if the beam pattern is euro or DOT, but it doesn't really matter as you are not allowed to modify any headlights as per DOT.... so while the beam could or could not be legal, the entire assembly is not technically legal". Headlight modifications are not legal unless you get it verified by DOT ;) . But David, I thought we cleared this up, no? Dan did a ton of research, dug up the various specifications for DOT (there are many) and our beam pattern does seem to conform to DOT standards. Some DOT beam patterns are wide and even (like ours), and some DOT beam patterns are more narrow and brighter in the center (like yours). Which type someone prefers (even and wide, or narrow and brighter in the center) is up to them. Personally I think the even and wide beam pattern lets you see more of the road in a less intense manner, but you seem to like the super bright long throw spotlights. Cool. To each his own. :):dunno:

Fact of the matter is, (as far as I can tell) our lights are DOT beam patterns. Does this matter? NO! Because you can't legally modify lights under DOT regulations. That means the headlight kits you want to sell, and we already sell are not DOT legal. Plain and simple. So we can argue beam pattern till we are blue in the face, but at the end of the day, none of our lights have a DOT stamp on the housing. So can we leave the DOT discussion there?

And if you are obsessed with having your car DOT legal, remember that our motors (20b) shouldnt even be on public roads as it was never registered by the department of transportation as a legal engine in the US. It was never verified by any agency for use on US roadways, nor was it in any car that was ever sold in the United States, and as far as Johnny Q. Public is concerned, you and I are both in violation of the law ;) How do you like them apples? :icon16:

-Heath

If you want to read more on beam pattern legality:
ECE low beams are characterised by a distinct horizontal "cutoff" line at the top of the beam. Below the line is bright, and above is dark. On the side of the beam facing away from oncoming traffic (right in right-traffic countries, left in left-traffic countries), this cutoff sweeps or steps upward to direct light to road signs and pedestrians. SAE low beams may or may not have a cutoff, and if a cutoff is present, it may be of two different general types: VOL, which is conceptually similar to the ECE beam in that the cutoff is located at the top of the left side of the beam and aimed slightly below horizontal, or VOR, which has the cutoff at the top of the right side of the beam and aimed at the horizon.

I just don't want to quibble back and fourth. Can we both get back to making parts or something more productive? :angel: :ugh2:


PS: Sorry to the OP for getting so far off topic, this would be better suited for discussion in David's thread. How this got started in your thread I don't know, so my sincere apologies!!!

Dan and I are going to meet to discuss our differences. And for the record, I am not selling nor intend to sell a light kit. Here's to getting back to being productive as you say :)

Wow, so much debate over beam pattern of projectors.... I dont really see what the big deal is here.

FWIW, I borrowed my mom's '04 RX-8 today and noticed her OEM Mazda HID's looked alot like what was posted previously.

snapped a quick picture
http://i272.photobucket.com/albums/j...87b30c9a_b.jpg

ill definitely jump on this if you can make this work.

I really appreciate everyone's input and think all the talk of lighting will help potential customers choose the right lighting for their setups.

Prices Should be available no later than 1 July 2010 :nod:

Idel

If the price is right I will take a set I love those knight sports head lights? Let me know please pm me when you have a price I would love a set? Thanks

Update guys, I have talked to several fabricators & they all recommend aluminum over the original steel. Aluminum will be more expensive cost wise but will cut down weight over the steel units.. Let me know what you guys think..

the issue of weight should be negligible at best since it should be no more than 5lbs of weight.

^
Reason why I asked is because the fabricators I spoke too said if these headlights were made today and not early 90's it wouldve been in aluminum opposed to steel. If there's still enough interest I will follow through on this if not then I will abort. The hardest part is finding someone willing to take on such a small project.

I have interest depending what it actually looks like.

Well the shrouds will only be made in carbon, if you've seen the frp ones that came stock with the KS kit their real flimsy. The brackets is the biggest hurdle because of the cuts, & angles. The fabricators I've spoke with, seem to not want deal with such a Small project. Fitment will have to be spot on because I would verify it before I ship.

Very interested! Please continue.

Mike