Photo how to - Lightwurkz DRL LED Halos

[rdono]

We just completed a few mods on the Cavallino Camaro and wanted to share a how to which demonstrates how easy it is to build your own DRLs. We used the units from Lightwurkz as we have past experience with their products and have been very happy with the quality. I also like the fact that they can provide halos that are the correct sized for the lamp on the Camaro. The final product will be the brightest LEd halo on the market and it will fill the lamp, not sit off center. The total time to make these mods was about 4 hours not including removal of the lamps from the car. Tools needed are only a Dremel tool with cut-off blade, a air sander (DA in locked mode) and a solder gun.

If you do not access to a air sander a belt sander with fine grit paper will work or you can simply place paper on a flat surface and hand sand the parts.

[rdono]

The first thing you need to do is separate the lens from the housing. To do this make a cut with the cut off wheel right on the factory joint seam between the lens and the housing. Your cut will be a tad thicker then the seam so favor the housing.

Notice in the second image that the raised portion of the lip is still in tack, you will now remove that lip by making a second cut.

The last image shows the housing.

[rdono]

Here is another image showing the difference of the two cuts required. In this case I have cleaned up both only to show you the difference. (image 1)

After the final cut you will have to remove the waste (image 2) and then make sure the cut surface is flat. This is where we use a air sander with 80 grit paper. (image 3)

We want to get full contact so take time to make clean cuts and it helps during sanding to use a felt marker to "paint" the surface so you can better see what you are doing (image 5&6). The more care you take the better the outcome.

[rdono]

Now we "pull off" any sludge from the DA sanding (image 1) and finish off by lightly hand sanding with 180 grit paper and kissing the corner (image 2&3).

Now we make a trial fit (image 4) to insure that we have mostly full contact, and I suggest you tape the ring in place (image 4) place the lens over the ring (it will actually fit snugly so you can test fit the lamp to your bumper if you like. (image 5) Note image 4, you will need to notch the lens housing for the wire, I prefer to have the wire on the top of the lamp, I also insist that we get the lens back on with the lettering on the bottom, thus a stock factory look under close observation.

[rdono]

Now the fun begins! First we position our ring onto the housing and use tape to hold it in place until we tack melt it (image 1). Using our iron we simply melt the plastic of the housing into the plastic of the halo. This is a simple process, just dip and pull the plastic parts together (image 2). We make about 3 -4 tacks around the unit, removing the tape as we go. (image 3&5). Somehow it is more difficult to post images here then build the bloody lamps, image 4 shows the weld process completed.

[rdono]

Now one word of caution and another reason I prefer the Lightwurkz products, you do not want to hit the circuit board in the halo. You can see where it is and these units have a healthy amount of plastic on them but DO NOT BE STUPID!

You can now clean the lenses and place them over the LED rings, they will actually snap into place. Now toy again need to use the melt-weld process. To do so, just turn the lamp lens face down and weld from the LED ring to the backside of the lens surface. By now you will be expert at melting plastics together and can forever leave the glue process to the amateurs.

I now place a bead of silicone clear (image 1) over the joints to seal out all water. You can use soapy water or glass cleaner to smooth out the bead of caulking. Just lightly spray windex on the bead and smooth with your finger. Image. The final result is displayed in image 2&3. Note the weld strokes on image 3.

The last image is the face of the finished product. Let them cure overnight and your ready to re-install.

[rdono]

Ok for now, tomorrow I will post images of the lights installed and operational.
This project can easily be performed by anyone with some common sense and basic mechanical skill.

Footnote: late today we fired up the assembled system and I have to tell you, if you do this plan on replacing the factory halos with those from Lightwurkz, You will see what I mean when I post the images.

The projects on the Cavallino Camaro just keep piling up!

[SNV]

Looking good . Can't wait to see them finished.

[Shuffler]

Aftermarket are so much better thsn factory

[rdono]

Here are some images of the completed project. The Lightwurkz halos in the DRL in full straight on sun are very bright. I included an indoor shot as well.

Again if anyone is interested in halos that look like they belong in the factory DRL's the project is easy. Just follow the steps outlined here. Have fun.

[Alain]

if i send you the DRL lights will you do this for me at a descent price? let me know bro, PM me.

[SNV]

They look great! I'm sure the price wasn't bad for parts?

[Topdown]

I know this is an old thread, but does anyone have the part numbers for the LED halo's used?

Thanks!

[rdono]

call Lightwurkz in SF, CA. or better surf the web. They sell mostly via ebay.