ClubCJ - The CJ Lancer Club

Hey guys,

As promised, here is the making of a custom CZ4A MR HL.

Parts include:
1. OEM CZ4A MR projector HLs. Sourced from Yahoo Auctions Japan (YAJ)
2. Mitsubishi Starwagon 3" halogen projectors. Sourced from YAH
3. S2000 (AP2) shrouds from HLs. HLs sourced from wreckers


Method & tools to open and seal HLs:
- Heat gun
- Phillips head screw driver
- Large flat head screw driver


Lets get to the pix:

MR's pulled apart. Gees, how many parts








This pic shows:
* 3" CZ4A projector lense on the left
* 3" Mitsubishi Starwagon (early 90's model) projector lense on the right. Theres quite a difference in projector height. Why have I made the comparison?




You can see the CZ4A lense with fine indents on the surface. This is designed to "blur" the edge of the light output and make it easier for on comming traffic.




You can see the Mitsubishi Starwagon lense is super smooth. This will make the edge of the beam pattern nice and sharp. I will be using these babies and ditching the OEM CZ4A lenses.




OEM CZ4A lense output:




Swapping out the OEM lense for the "clear" Mitsu Starwagon lense:




CZ4A Bi-Xenon projector. You will notice that the cutoff shield "Steps" up to the right, meaning it is designed for Right Hand Drive conditions. Finding this out pissed me right off. Now I have to modify it to "Step" up to the Left for Left Hand Drive conditions. More bloody work








Cut off shield in "Low Beam" position.




Cut off shield in "High Beam" position thanks to the movement of the solenoid. The cut off shield actually comes down further. The sticky tape wasnt doing a good enough job.




The front of the CZ4A projector has been divided into 2. In order to modify the light output for more bling I didnt have a choice but to Dremel this piece.




* The Mitsu Starwagon 3" lense mated to the CZ4A lense holder.
* The ditched CZ4A 3" lense on the right.




The Mitsu Starwagon lense is slightly larger and had to be trimmed with an angle grinder. This resulted in chips along the edging. Luckily it will not be noticable:
* once the project is finished
and
* in the light output.




2nd UPDATE: 22/04/2010


How will a can of NITRO help with my project?




Now I have fabricated some brackets to hold the lense together.






NITRO can cut up. Will be using this to create a SHIELD infront of ALL 4 projectors. These will be painted white to give a "White" looking projector. I have a few tricks up my sleeve with the final result of this mod
An example of a "RED" looking projector can be seen on this Evo VII - IX headlight:
http://i264.photobucket.com/albums/ii19 ... G_5095.jpg




A template of the shield that I will cut out




The shield almost complete. Still requiring a few more bends then a coat of white paint




Using a pair of S2000 (AP2) shrouds to cover up the 2nd projectors.






I had to dremel away at the top of the housing to fit the S2K shroud. I was surprised at the minimal dremelling required to make it fit








The gaps around the S2K shrouds are noticable but once the black paint kicks in it should reduce some of that visibility.








Painting stage




Shields for the projectors




Indicator housing




Parker housing




Lense holders for the 2nd projector




S2000 shouds to cover up the 2nd projectors. Shown with white rings but eventually went ALL black




DRL housing to fit the 2nd projectors



Internal housing. Rings painted white but eventually decided to go ALL black






These puppies are finished














Headlights on the car
















Thanks for looking

Good job.

I'd be happy with the Evo X projectors themselves TBH, I wouldn't worry about changing the lens but good on you for the effort mate!

Good work, and kudos for sharing your wisdom

I am like Adrian... Stock would be good.... with a little love they would be awesome

i take you made these for some one in the US as per your changing of the shield direction.

I have since learnt from that experience and have found a direct replacement 3" clear lense.
- No hack work required
- direct plug n play

Called the: "ZKW-R" lense. Its a replica BMW lense. Wish I had of known about it before doing the hack work.
It produces the same output, sharp with a blue edge like the exotic cars:
- 300C's
- BMW
- S2000
- HID VE Statesman's

These can be sourced from US headlight modifying companies. eg Theretrofitsource.com

Trust me when I say that the results are worth it.

What sort of rough price would you be looking at including the OEM unit. Obviously fluctuates buying at auction though...

Blakey wrote:i take you made these for some one in the US as per your changing of the shield direction.

I made these for a mate in Alice Springs. I ended swapping the projector from one of my JDM MR sets. The US projector is sitting at home.

LZY_EYE wrote:What sort of rough price would you be looking at including the OEM unit. Obviously fluctuates buying at auction though...

I could link you to a dirt cheap (good condition, no bulbs, no ballast) LHS MR HL from Japan. Works out to be roughly $165 shipped to Melb I would so buy it but im scavanging all my money for my engine build.

The other parts are relatively cheap.

- ZKW-R lense from $30US
- 2nd Halogen projector from $35US

Hmmmm when I have some cashola I might get in touch with you...

That turns out to be quite reasonable...

Yeah I would be in on that too (as well as a lot of people I guess):D

Mods / Admins,

I appologise in advance if im breaking any forum rules on posting links to items forsale from non-forum vendors. Please delete if this is the case.

Id like to give members a clear cut understanding of how much parts cost to make custom headlights.

As for this cheap LHS MR HL, I would not be umming and arhhing on this item. Auction closes Wed, 21st, April, 10:15pm Darwin time (30min extra for you southerners)... you could slowly accumulate all the parts needed over time. Trust me when I say this is a good deal. Ive been monitoring Evo VII - X headlight prices everyday since Feb 2009.
If anyone is serious about it just shoot me a PM and ill send you the link. Youre more than welcome to use my Import Monster account to buy the item. I am a VIP member due to the amount of money I have spent with them. They give me cheaper shipping rates as a result. I have had quite a few EvoOZ members use my account to buy parts for their cars (my Alice Springs mate with my modded MR HLs as well)

* ZKW-R clear lense ($30US):
http://store.theretrofitsource.com/index.php?cPath=29

* 2nd halogen projector ($35US):
Not listed on the website but was quoted $35US for the cheapest projector

* ALSO for got to mention a BMW E46-R replica shroud ($25US):
http://store.theretrofitsource.com/inde ... d0fbb3a2a9

I saw a fellow member who had this done on his MR for around $400 from Autojoy in Parramatta and honestly, it looked a bit wonky on the Evo MR.

Im keen to know what "wonky" looks like. Post a pic

Don't have it on me because we couldn't take photos (LEDs + conventional camera at night = fail). Basically it was angel eyes which followed the shape of the reflector in the headlights; and the Evo MR doesn't have perfectly circular reflectors.

2nd update in 1st post. check it out

You have maaaad skillz bro