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2013 Headlight Hawkeye Build Thread

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Gs Legacy Apprentice

Gs Legacy

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Hello Legacy Forum

 

I am a new member on a mission. I want to transform my 2013 legacy headlights into hawk eye style drls. I have searched online and found this thread. http://legacygt.com/forums/showthread.php/new-2013-headlight-219429.html?t=219429

 

However, being that all the picture links are dead and all the resources are in Chinese, here I am starting from scratch.

 

The goal. Turn these:

http://www.partsvilleauto.com/wp-content/uploads/imported/7/2010-2011-2012-2013-2014-Subaru-Legacy-Outback-Halogen-Headlight-Right-RH-OEM-231244910837-500x334.jpg

 

Into This:

http://www.automoblog.net/wp-content/uploads/2014/02/2015-Subaru-Legacy-4.jpg

 

Quality Like:

http://fourtitude.com/wp-content/uploads/2012/12/a6-headlight.jpg

 

LEDs

I decided to go with the 5050 SMD LED lights that you find on ebay(there goes my quality...lol). The reason being is that they are the most abundant and they don't produce a lot of heat. To be extra "Cautious" I went with the LED's that have the waterproof housing. <---Warning against this if the water proof shield peels off then color changes.

 

Higher quality LEDs

Problem: They produce more heat so I would have to worry about dissipating that heat. Also, better quality led's would require me to create my own led board...and I don't got time for that...lol

 

Acrylic medium

So I decided to go with acrylic as my medium which light will shine through. I purchased several plexiglass options. 1/8", 1/2" , 1" and stamped. I wanted to use the 1/2" or 1" to make a frosted DRL options. I found that trying to get a uniformed "frosted" look was not so simple. The best way to do this is to use a sand blaster. Being that I don't have a sand blaster and can't afford to get one, I went a different route.

 

Important Specs: In all my attempts I want the light to be uniformed as possible (homogeneous). This means I want it to be evenly spread form any viewing angle as with the Audi style DRL. Essentially you can't tell where the source of light is coming from. Also I want the LEDS are not visible when they are turned off.

 

So I watched this Snells Law video here (Just watch the until 1:06):

 

Watched this:

 

Then read this article(http://www.plexiglas.com/export/sites/plexiglas/.content/medias/downloads/sheet-docs/plexiglas-optical-and-transmission-characteristics.pdf that basically says plexiglass has a critical angle of 42.2 degrees. That being said I took a piece of 1/2" and created the following.

 

 

1st Mock Up

http://i7.photobucket.com/albums/y260/moreitems4less/2ABFF132-968E-4FE8-8576-B0C3D7CEA1B1_zpsl95izb5f.jpg

 

http://i7.photobucket.com/albums/y260/moreitems4less/5686FB0B-B1F0-46AF-8611-3D3F9600546C_zpsoh92al4h.jpg

 

http://i7.photobucket.com/albums/y260/moreitems4less/0C2B0604-DC5C-424E-8799-4304D4AD2776_zpswvzjidjc.jpg

It is coated with nail polish (my wife's) on each end.

http://i7.photobucket.com/albums/y260/moreitems4less/AB43670C-87CA-4D4E-922D-359309105DC2_zpsy3bplx1e.jpg

 

http://i7.photobucket.com/albums/y260/moreitems4less/BB9B48A9-C4FD-400F-B8EB-6ACBD7FA0024_zpsjrxgwiio.jpg

 

Light production:

http://i7.photobucket.com/albums/y260/moreitems4less/C65ED06E-99F9-47B4-98B2-31422A65D4B3_zpsicamkels.jpg

W/Flash

 

http://i7.photobucket.com/albums/y260/moreitems4less/8AF5A8C8-7547-45C5-946F-760398C60A21_zps0ufkjc95.jpg

W/Out Flash

 

The lighting out put was so bright and evenly spread that I was in heaven. :spin: I really was happy that you could see light at any viewing angle. Though the first mock up was good, the rod was too long. It wouldn't work in our headlights. So, I decided it better make a shorter version using the same specs as my 1st mock up. I made the following.

 

2nd Mock Up

 

http://i7.photobucket.com/albums/y260/moreitems4less/4B307063-F93C-4DAE-AC2B-6A2C23883BE2_zpsto5gvz2m.jpg

 

http://i7.photobucket.com/albums/y260/moreitems4less/4CE65165-7D32-4ED0-9A38-2839010F7F06_zpsonlqjj74.jpg

 

Light output

 

http://i7.photobucket.com/albums/y260/moreitems4less/DA49D85C-4DD6-43F2-88EE-EFE5603BF30F_zpsbvrshul5.jpg

W/Flash

 

http://i7.photobucket.com/albums/y260/moreitems4less/DA2F176B-62CB-4A35-B012-3401AEAEC310_zpszajzioti.jpg

W/O Flash

 

As you can tell, its a night and day difference. I was mad!!!!:nono: I tried everything to replicate the light output of my first try in a shorter length but I couldn't. So I decide to change it up completely and went with the following:

 

3rd Mock Up

http://i7.photobucket.com/albums/y260/moreitems4less/6762FC92-114D-470B-AE40-BA97B4DCBEB7_zpshusjl26l.jpg

 

http://i7.photobucket.com/albums/y260/moreitems4less/2120B1DE-35FA-485A-990A-201CD30396E7_zpsefctpiwy.jpg

 

http://i7.photobucket.com/albums/y260/moreitems4less/5C0696CA-9195-45B8-AB75-CE1CDA115D41_zps9bfgpui0.jpg

 

This 3rd gave me the best uniformed light and hides the Leds when they are turned off. However, the LEDs must be a certain distance away from the shield. If it isn't then the light source is visible. Also in the picture you notice that my shield is rounded. To get better light output but I will have to flatten that surface.

 

Also the great test advantage is the I will have a flat surface to work with then I install these on the OEM headlights. I can shape them and adjust them appropriately.

 

Light comparison of all three

http://i7.photobucket.com/albums/y260/moreitems4less/376FEF2D-080A-41D8-904E-38FC8071447A_zpsmxdhssba.jpg

This picture is horrible ( Left: 1st Trial, Left Middle: 2nd Tiral, and Right: 3rd Trial)

Whats to come:

- Better photos

- Setting up a jig to create accurate bends and cuts to match oem headlight specs.

- Creating a final mockup

- Figuring how to wire multiple inputs to one relay. (Any automotive electricians out the feel free to chime in)

- Final installation :)

 

I do apologize for any grammatical, spelling, scientific errors. I will go over everything and fix them all. Just wanted to get this posted!

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Gs Legacy Apprentice

Gs Legacy

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Bending Form:

 

So today I had the time to make a form for bending the acrylic. The form is no way close to the spec of the oem surround. I just want to it to create sharp/clean bending lines as well as a flat surface for the light to go through.

 

I basically had to make a base and then something to press the acrylic into the base. The base is set at an angle so it could have that "pizza slice" look. I used 1/2" oak to make the base. The "press" is made of oak as well however I had to make it 2/16 of an inch thinner than the jig. Doing this assures that the acrylic has room to move. Also, the press is made longer than the jig. This is so I can slide it (From wide end to small end) to make a tighter sharper form.

 

 

The Base

http://i7.photobucket.com/albums/y260/moreitems4less/107CF4A5-7EE4-4DF1-890A-A8130B79CF9E_zpsg8zfkilo.jpg

 

http://i7.photobucket.com/albums/y260/moreitems4less/0CB246EE-93E1-4303-BFB3-2CD004EAB75C_zpsa8p44gww.jpg

 

The Press

 

http://i7.photobucket.com/albums/y260/moreitems4less/70FC84BE-73A1-4B33-BF97-91E530534F5A_zpsfmbukaux.jpg

 

 

The Results

 

So after trying out my new press/jig. I found out that heating the acrylic evenly is going to key in getting great results. Right now I am using a butane torch and passing it back and forth on the acrylic. This method works well however you can hear cracking if you missed a spot. :eek: I am going to research different ways to heat the acrylic evenly but I will probably just keep using this method until then.

 

Here it is:

http://i7.photobucket.com/albums/y260/moreitems4less/120BEB3C-BF37-4FBD-94A4-CCC8AC9076DC_zpsov68btj6.jpg

 

http://i7.photobucket.com/albums/y260/moreitems4less/9C23EBEA-6647-4B62-870B-7CA03484878F_zpsmf1x49vx.jpg

 

http://i7.photobucket.com/albums/y260/moreitems4less/79F19E79-A442-482D-900D-DAA1414F6860_zpsn2xxisqx.jpg

 

 

Pictures with LED's in it:

 

http://i7.photobucket.com/albums/y260/moreitems4less/639F88A9-AD0B-47F8-B788-46C69E523480_zpssjcl8tuo.jpg

 

With LED on

http://i7.photobucket.com/albums/y260/moreitems4less/74B6B545-284C-4309-8354-5051F10282B4_zps1l9xwwgz.jpg

5' away in sunlight

 

http://i7.photobucket.com/albums/y260/moreitems4less/A0A60B97-DB50-4C06-8CEB-E07A00B11420_zps9segq97m.jpg

5' away in shadow

 

http://i7.photobucket.com/albums/y260/moreitems4less/D6E3F6B2-BA50-44B4-AB85-24242A36A840_zps9lok622h.jpg

Close up in Sunlight

 

http://i7.photobucket.com/albums/y260/moreitems4less/5EC1F944-B6B8-4396-A3A9-C26F389D1700_zpslk4yybvc.jpg

Close up in Shadow

http://i7.photobucket.com/albums/y260/moreitems4less/42D38E30-8E03-4C52-BEBF-C09C050AE45B_zpstfx2zkb0.jpg

In sunlight

 

http://i7.photobucket.com/albums/y260/moreitems4less/62E0B5D7-40DD-4971-8561-47D84EA0DC49_zpshkop6cyf.jpg

 

http://i7.photobucket.com/albums/y260/moreitems4less/C9D927F8-9356-42E4-BF34-877E11FFAD5B_zpssdsp1ut2.jpg

 

http://i7.photobucket.com/albums/y260/moreitems4less/C9D927F8-9356-42E4-BF34-877E11FFAD5B_zpssdsp1ut2.jpg

LEDs

 

Soo....5050 smd leds are not going to cut it in the daylight....:nono:. This means I'm going to have to eat my own words and build my own led strip!.:hide:

 

The 5050 put out about 15 lumen per led. That definitely can't compete with the sun! So I am thinking about looking into these which produce about 100 lumen per led or these that produce 50 lumen per led. I have never soldered anything before so this is going to be fun!!!! I will try to get these order and installed asap. In the mean time what the heck am I going to do with 3 meters of 5050 smds!!!!!

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Gs Legacy Apprentice

Gs Legacy

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The GOOD: Upgrade LEDs

 

So after posting my Sat update. I started to do some research. Much thanks to nstg8r and StevesH6 I started to look into larger and more powerful Leds. Building my own led board would require and electrical engineering degree...lol. It is a lot more complex than soldering led's to a board.

 

Google maps however would end up being my savior...lol! After doing a quick search a found a local LED dealer (The company creates billboard led's). Drove over to the store and ended up meeting the owner. We ended up talking for a while, and she wanted to see the project. The reason is she wants to take her company into the automotive lighting market but wants a representative.

 

Anywhos, I told her what I needed and she guaranteed me that she had something. She said the light would be able to be seen in the daytime. So I purchased 20 pieces went home and I was in love! These lights were great indoors but outdoors was the real test. DSLR in hand I headed outside. It took some quick measurements and found that the top part of the hawk-eye bezel sat about 31" above the ground. So I set my new Leds w/lens setup at the same height at took photos.

During this time my neighbor (that one nosey neighbor) come out. He was very curious and asked me why I am taking pictures of "the light". I told him I was working on a project but then instantly got excited! He was able to see the light from across the street in his driveway.(see last picture)

 

So now all I am waiting for is my d2s ballast to come and then I will be doing official install!! I can't wait.

 

Other news:

The new LEDs come in different colors. I asks her if they came in amber and if they created a switchback version. She will be looking into it!! For those who don't about know switchback leds. Switchback leds will give one the ability to use the hawk-eye led as a turn signal.

 

The Bad:

 

My only complaint with the new LEDs is that it comes in one standard size/width. Due to this it is going to be difficult to get light to reach the smaller ends of the hawk eye (ends towards the grill)

 

http://i7.photobucket.com/albums/y260/moreitems4less/_MG_7658_zps081dabc2.jpg

Indoor Close Up

 

http://i7.photobucket.com/albums/y260/moreitems4less/_MG_7664_zps440eb506.jpg

Outdoor Close up (at 31")

 

http://i7.photobucket.com/albums/y260/moreitems4less/_MG_7668_zps579a1710.jpg

http://i7.photobucket.com/albums/y260/moreitems4less/_MG_7669_zpsab6b9203.jpg

15 Feet

 

http://i7.photobucket.com/albums/y260/moreitems4less/_MG_7670_zpsfd12eb8a.jpg

http://i7.photobucket.com/albums/y260/moreitems4less/_MG_7671_zps0d7ecbc7.jpg

25 Feet

 

http://i7.photobucket.com/albums/y260/moreitems4less/_MG_7672_zps9b917bc1.jpg

~40 feet

 

http://i7.photobucket.com/albums/y260/moreitems4less/_MG_7673_zps0e1eb97c.jpg

~60 feet

 

http://i7.photobucket.com/albums/y260/moreitems4less/_MG_7674_zps7d1c1b55.jpg

~80 feet

 

http://i7.photobucket.com/albums/y260/moreitems4less/_MG_7676_zpsd470f1f4.jpg

~100 feet. (exactly where I was standing talking to my neighbor)

 

http://i7.photobucket.com/albums/y260/moreitems4less/_MG_7678_zps081d2e05.jpg

Standing next to the led strip. My neighbor was standing right were the deciduous (evergreen) bush is in the center of the photo. Probably close to 200ft away.

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Gs Legacy Apprentice

Gs Legacy

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Just to be thorough as possible, I took a couple of photos to mimic the 5050 smd shots from earlier.

 

 

http://i7.photobucket.com/albums/y260/moreitems4less/_MG_7682_zps7eefddc0.jpg

http://i7.photobucket.com/albums/y260/moreitems4less/_MG_7683_zps2e26b700.jpg

Without lights on

 

http://i7.photobucket.com/albums/y260/moreitems4less/_MG_7688_zps4844ba9b.jpg

http://i7.photobucket.com/albums/y260/moreitems4less/_MG_7689_zps0e3dd38d.jpg

With lights on

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Gs Legacy Apprentice

Gs Legacy

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Looks cool! Nice work! Looking forward to your final outcome!

 

I'm planning to upgrade mine later in the spring to a more powerful LED from 3W to 6W.

I can't believe you are going to open up those headlights again. Doing that almost made me change my mind!

looks good. interested to see the outcome

Thanks. It should be soon!!!

 

Subbed. Good work so far

 

Thanks

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Richievn Apprentice

Richievn

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good Stuff. Considering redoing mine as well. Those cheap led strips burnt down to frequent. I bought the same Stuff like Gbjora888 but the light wasn't that bright so I bided up not installing those. Release show me a better brighter led once you found one. Thanks heap
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Gs Legacy Apprentice

Gs Legacy

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good Stuff. Considering redoing mine as well. Those cheap led strips burnt down to frequent. I bought the same Stuff like Gbjora888 but the light wasn't that bright so I bided up not installing those. Release show me a better brighter led once you found one. Thanks heap

 

So I must know. How did you do your headlights. It looks like you cut the bezel and then used a white plexiglasss sheet. Am I correct? Fitment is my major problem right now since my leds are pretty big. LMK what you are using. LOVE your lights. Also, how'd you do the switchback/turn signal wiring?

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Richievn Apprentice

Richievn

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So I must know. How did you do your headlights. It looks like you cut the bezel and then used a white plexiglasss sheet. Am I correct? Fitment is my major problem right now since my leds are pretty big. LMK what you are using. LOVE your lights. Also' date=' how'd you do the switchback/turn signal wiring?[/quote']

 

Yeah I gotta cut the bezel (and broke it finally) and glued a cut flexiglass into it. I thought of acrylic before but could find a decent one thats bendable. Mind you that the space behind is very tight and I could not slide another acrylic rod into it. Good try by the way.

 

The wiring is not difficult as the led strip came with 2 colour themselves and I only tap into the respective wires.

 

Looking at your work and preparing mine .. ;););)

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Gs Legacy Apprentice

Gs Legacy

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Yeah I gotta cut the bezel (and broke it finally) and glued a cut flexiglass into it. I thought of acrylic before but could find a decent one thats bendable. Mind you that the space behind is very tight and I could not slide another acrylic rod into it. Good try by the way.

 

The wiring is not difficult as the led strip came with 2 colour themselves and I only tap into the respective wires.

 

Looking at your work and preparing mine .. ;););)

 

1st: Hats off to you for being able to put anything in that space.

2nd:The Led's that I'm using only comes in one color. I would have to use two different Led systems.So, for me to use the actual use mine as turn signals it will require some modification. I would want to the white light to turn off while the amber is working. For now its not a big deal.

 

:icon_idea Just had a crazy thought that would have made this whole thing simpler. It would be easier/look nicer if you used a hollow plexiglas tube. Like this one (http://www.tapplastics.com/product/plastics/plastic_rods_tubes_shapes/clear_acrylic_tubes/141). All you would have to do then is cut it in half, add lines (like 2015 legacy pics), place lights behind it, and you are done!!!

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Gs Legacy Apprentice

Gs Legacy

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http://i7.photobucket.com/albums/y260/moreitems4less/9F4E9EF4-B2EB-40EE-97C5-1795BDEC7CE2_zpsf6tcucgq.jpg

http://i7.photobucket.com/albums/y260/moreitems4less/339331FF-2048-4D82-8755-8168FA557464_zpsh41fr6dq.jpg

http://i7.photobucket.com/albums/y260/moreitems4less/12153C70-9238-4398-9013-E3654153F0D1_zpsc8gnyfnw.jpg

Latest update

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Gs Legacy Apprentice

Gs Legacy

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Good effort man, keen to see how this turns out once fitted

 

Thanks

 

Great work! Make sure you don't overextend it and try to test putting the glass cover every now and then. I remember the gap in between the glass cover and the hawk eye or eyebrow is really tight.

 

I definitely checked and everything turned out great! Tons of space.

 

Unfortunately I got called into work today so I won't be able to finish up till next week.

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