Turn Signal Projector Lens + Sunlight = Melted Housing
 

I would like to revive this thread in regards to the section of the housing in front of the turn signals in which the paint melted and cracked.

I had a new set of headlights modded with projector lens for the turn signals, and the same section showed signs of damage after a week of driving. I had to ship one of the headlights back for repair, and the modder discovered that the projector lens in the turn signals was casting an image directly onto the damaged site no matter where the light source was at. So this pretty much concludes that the combination of the matte black surface and the sun shining through the projector lens melted the housing.

So for those of you who would like to convert the turn signals to a projector style, mask of the section of the housing in front of the turn signals and leave it chrome. That will reflect nearly all of the projected sunlight from the lens and keep it from melting.

It was a bit late in the design for my headlights, so I will keep this in mind if I ever work on Version 3.0 of my headlights.

I stand corrected that CinCity was NOT at fault for this issue.

regardless of who or wat caused this i still do not have the warm and fuzzy for painting headlights. they look great no doubt, but in terms of regular use and durability you're in unchartered territory.

my daily work is supplying parts to OEM customers and especially automotive customers are very keen on UV and extreme temp exposure. there is a reason for that and do not take lightly. chances are you will make your car perform worse.

That's so odd, we've had the projector style turn signal on a customers car for a little bit more than 2 months and I've seen his headlights a few days ago and there wasn't any issues with the housing.... must be something else?

I thought it was heat from the HID bulb causing the paint to bubble, but he also tested it today and confirmed heat wasn't an issue from the bulbs.

Attached are some pictures with and without flash. The projected light is from the ceiling light in the garage. You can see the area where there's always light projected to the damaged surface from above.

The CinCity headlights had it bad. That section was warped and the paint pretty much cooked and cracked. The new ones will probably end up the same, so in a few years I may redo the design and leave this area unpainted.

Flash
http://www.the370z.com/attachment.ph...1&d=1307585948

No Flash (Observe the ceiling light cast to the damage location)
http://www.the370z.com/attachment.ph...1&d=1307585948

Another angle without flash showing the paint bubbling
http://www.the370z.com/attachment.ph...1&d=1307585948

I'm currently thinking of ways to fix this for headlights that already have the projector lens mod and already painted. Going back to chrome isn't an option and it'd look pretty out of place on a housing that's painted black. Perhaps a gloss black metal piece glued to that area? I don't think that'll look too bad and it'll handle the heat fine.

Basically a shade or lid similar to traffic lights. It keeps the sun from shining above the lens causing the burn below it.

that would work, but I don't think it'll look as good that way. I've got a couple ideas but still trying to figure out which one will still look good and wouldnt change anything drastic. Will definitely post updates when I can figure something out

Another idea is a spacer to push the lens deeper in the projector housing.

How about tinting the bottom half of the projector lens. would that work?

I think the amount that it would be needed to be pushed back would make it look pretty off. It would be basically using the halo as the "eyelid" protection from the sun

well, if its only the bottom half, that would mean the top half is still subjected to the sunlight, so yes it'd help but I dont think it'd help enough. Also, it would restrict some of the output from the turn signal.

If you look across different forums such as clublexus and s2ki, they have similar issues too. All the issues are from the projector lens focusing too much light and melting the housing. The "fix" from Honda was that for the AP2 headlights there is an aluminum plate integrated into the housing in that area so it doesnt melt. Earlier today I went to buy a sheet of aluminum from home depot, I will paint it using high temperature enamel, and placing a carefully cut strip in that area. I think this method will be the most practical without looking ugly.

AP1 Headlight blisters/bubbles... - S2KI Honda S2000 Forums
2011 Headlamp Bubbling Defect - Club Lexus Forums
06-08 Gloss Black Painted Headlight Blistering Problem! - MY350Z.COM Forums

I will post pics of the fix soon.

I've decided to have my whole lens tinted. They are at the shop now being done. I think it'll look cool and be something different anyhow. The only thing I had to sacrifice was doing dual demon eyes. I don't think it would look right with the tint.

I completed my first set of "fixed" 370z headlights today. I bought a sheet of aluminum and shaped it to the curvature of the housing, then painted it with high temperature black paint, and jb welded it on. I think this should be a good fix since the aluminum isn't melting until over 1200F and the paint is rated for 500F.

I'll post pics tomorrow.

https://scontent-b-sjc.xx.fbcdn.net/...04412260_n.jpg
https://scontent-b-sjc.xx.fbcdn.net/...65386817_n.jpg

It's honestly not very noticeable IMO and definitely doesn't look too bad. Let's see how these hold up.

Can you cut one up and form it into the same parabolic shape?

yeah, the aluminum sheet is bendable. a little patience and skill, and it'll form to the curvature pretty easily