Right here goes.
I wanted to make a cup racer style headlight intake as I think they look awesome on the Cup Racers and are completely functional. My plan was to get a standard headlight, take the lights out of it leaving just the lens. This would be used for trackdays only as this would make the car illegal - removing the indicators and lights.
I started out by buying a near side headlight off ebay and when it arrived, I measured up and decided what size intake duct to use. I settled on the 150mm x 75mm as this seemed large enough and would not have to be formed much to bend around the inside of the lens. I picked up some Flexible black 76mm ducting hose. The duct came with a stepped outlet, 63mm and 76mm. i used a hot knife to slice off the 63mm step and was left with the 76mm outlet.
First thing i did was to cut out the inners of the headlight whilst leaving the 3 mounting lugs in place. this was done with a sideways cutting drill.
Next job was to place the duct upto the back of the lens and mark out the hole to be cut.
The lens was then cut to size using a hacksaw blade. I started off drilling holes in each corner then sawing between them.
The duct was then heated up and pressed up against the back of the lens so it would take the correct shape. It was then bonded in place
Finally the assembly was sprayed in a matt black plastic based paint.
I think its looks sweet! the hosing will be attatched to the duct using a jubilee clip as the duct is strong enough to take it. the Front bumper will have to be removed in order to install the intake but there is a guide on here detailing how to do so.
Mike.
