Custom headlights by JnC, part III.
Joined: Sep 2008
Posts: 78,249
Likes: 20,202
How long did you wait? He's usually in the garage in an apron and thong working on headlights. Being on here and responding to everyone's every whim would hurt production turnaround in a major way.
Thread Starter
Former Sponsor
iTrader: (12)
Joined: May 2004
Posts: 6,961
Likes: 351
From: Bedford, MA
Lol
I am a bit behind on responding to all the PMs, emails, text inquiries reason being that the shop is getting moved to NH permanently. Once everything is set I'll be sure to update everyone with required info.
P.S Moving sucks.
I am a bit behind on responding to all the PMs, emails, text inquiries reason being that the shop is getting moved to NH permanently. Once everything is set I'll be sure to update everyone with required info.
P.S Moving sucks.
Instructor
Joined: Jun 2011
Posts: 145
Likes: 6
From: Long Island,NY
Was going to ask if he does FX35 lights. BTW, JNC I finally installed my lights back in the spring. Amazing. I will post pics up soon. I think 7 months of having them sit in my attic, and finally ordering CBI's and doing the resistor mod...the wait was WELL worth it. He is a GOD amongst men( in terms of modding lights)
Thread Starter
Former Sponsor
iTrader: (12)
Joined: May 2004
Posts: 6,961
Likes: 351
From: Bedford, MA
Some of the recent work, I have been busy with family hence this thread is not getting updated as regularly as it use to 
Did this set for a customer from NJ who isnt a member on the forum, I am digging for more pictures but this the only one so far, it was inspired by Rondnyc's set.
Details
04 Headlights converted with 07-08 internals
Chrome bezel left in tact
Type S diffusers with amber painted matte silver
Main grey shroud painted matte silver
Partially painted matte silver turn signal reflector
ZKW-R lenses
Full lens restoration
Did this set for a customer from NJ who isnt a member on the forum, I am digging for more pictures but this the only one so far, it was inspired by Rondnyc's set.
Details
04 Headlights converted with 07-08 internals
Chrome bezel left in tact
Type S diffusers with amber painted matte silver
Main grey shroud painted matte silver
Partially painted matte silver turn signal reflector
ZKW-R lenses
Full lens restoration
Joined: Sep 2008
Posts: 78,249
Likes: 20,202
Very nice work, Farukh.
I never noticed that little detail coming off the side of the DRL toward the projector, those 2 ridges on the 07/08's. Very nice.
Do you tune all your clear projector installs? Just curious...I added 2 of those TRS spacers to each side at paperboy's recommendation and it definitely sharpened up the light.
I was also curious what the difference is between zkw-r lenses with or without the little notch in them. The set you sent me were both clear, but 1 had notch, one didn't.
Cheers
J
I never noticed that little detail coming off the side of the DRL toward the projector, those 2 ridges on the 07/08's. Very nice.
Do you tune all your clear projector installs? Just curious...I added 2 of those TRS spacers to each side at paperboy's recommendation and it definitely sharpened up the light.
I was also curious what the difference is between zkw-r lenses with or without the little notch in them. The set you sent me were both clear, but 1 had notch, one didn't.
Cheers
J
Thread Starter
Former Sponsor
iTrader: (12)
Joined: May 2004
Posts: 6,961
Likes: 351
From: Bedford, MA
^^ I am sure this has been mentioned many times but each ZKW-R lens is slightly different than the other, this variance is easily noticeable as you are trying to achieve the sharpest cut off. OEM lenses have these variances as well but you cant notice them as the output is blurry.
The notch is to make the fit easier with the E46 OEM bi-xenon projectors as they take these lenses as well. All other dimensions and focal point of the lens is the same.
In either case, I use one or combination of a few of the following methods to attain the sharpest possible cut off from the ZKW-Rs.
1) Shield adjustment, this may involve bending the shield forward or backward, not just in the middle but on the sides as well if needed.
2) Lens spacing, either with spacers or washers depending on what sort of batch of ZKW-Rs I am working with, some of them have a slightly higher focal point.
3) Shaving the lens holder.
4) Rotating the lenses.
The notch is to make the fit easier with the E46 OEM bi-xenon projectors as they take these lenses as well. All other dimensions and focal point of the lens is the same.
In either case, I use one or combination of a few of the following methods to attain the sharpest possible cut off from the ZKW-Rs.
1) Shield adjustment, this may involve bending the shield forward or backward, not just in the middle but on the sides as well if needed.
2) Lens spacing, either with spacers or washers depending on what sort of batch of ZKW-Rs I am working with, some of them have a slightly higher focal point.
3) Shaving the lens holder.
4) Rotating the lenses.
Great work though.
Joined: Sep 2008
Posts: 78,249
Likes: 20,202
^^ I am sure this has been mentioned many times but each ZKW-R lens is slightly different than the other, this variance is easily noticeable as you are trying to achieve the sharpest cut off. OEM lenses have these variances as well but you cant notice them as the output is blurry.
The notch is to make the fit easier with the E46 OEM bi-xenon projectors as they take these lenses as well. All other dimensions and focal point of the lens is the same.
In either case, I use one or combination of a few of the following methods to attain the sharpest possible cut off from the ZKW-Rs.
1) Shield adjustment, this may involve bending the shield forward or backward, not just in the middle but on the sides as well if needed.
2) Lens spacing, either with spacers or washers depending on what sort of batch of ZKW-Rs I am working with, some of them have a slightly higher focal point.
3) Shaving the lens holder.
4) Rotating the lenses.
The notch is to make the fit easier with the E46 OEM bi-xenon projectors as they take these lenses as well. All other dimensions and focal point of the lens is the same.
In either case, I use one or combination of a few of the following methods to attain the sharpest possible cut off from the ZKW-Rs.
1) Shield adjustment, this may involve bending the shield forward or backward, not just in the middle but on the sides as well if needed.
2) Lens spacing, either with spacers or washers depending on what sort of batch of ZKW-Rs I am working with, some of them have a slightly higher focal point.
3) Shaving the lens holder.
4) Rotating the lenses.
Great to know...yeah, putting in the 2 spacers, I was NOT able to reclip the lens retainer without breaking 1 side on both of mine.
It's holding tight, but still...I was thinking, how the heck can you even put another one in!Thanks for the clarification, I hope it's clear that I was really looking for education and not trying to complain about my zkw-r's being different. I appreciate the time you took to answer.
Honestly, man...after reading that, the price you charge is a friggin deal...tuning the lens is a fkn PITA.
J.
Thread Starter
Former Sponsor
iTrader: (12)
Joined: May 2004
Posts: 6,961
Likes: 351
From: Bedford, MA
Thread Starter
Former Sponsor
iTrader: (12)
Joined: May 2004
Posts: 6,961
Likes: 351
From: Bedford, MA
^^ Thanks, guys.
Another popular set up that I have been doing a lot of recently, the all clear look
Just finished this one
Details
2006 TL Headlights
All clear
USR clear diffusers
ZKW-R lenses
Another popular set up that I have been doing a lot of recently, the all clear look
Just finished this one
Details
2006 TL Headlights
All clear
USR clear diffusers
ZKW-R lenses
Thread Starter
Former Sponsor
iTrader: (12)
Joined: May 2004
Posts: 6,961
Likes: 351
From: Bedford, MA
Upgrading the lens with all the tweaking etc takes about 30 minutes, which is not a big deal, the real pain in the ass is making sure all headlights look immaculate. Being that the 3G TL headlights can be as old as 10 years (early 2004 models sold in late 2003) it would mean to resurface and clear coat all the headlights. To avoid and discrepancy I have adapted the practice of resurfacing almost all of my projects, hence is the reason why all the headlights that you see look almost brand new.
Between sanding, polishing, clear coating it takes about 4 hours to do the pair of lenses
Joined: Sep 2008
Posts: 78,249
Likes: 20,202
That's dedication...but it's also why you're known as "the headlight guy". 
Keep up the good work, Farukh. It's appreciated.
...and guess who has a TL that was built in August of 2003?
Also, not sure if anyone cares or has a fear of being able to revert to stock down the line, but I did this last set of headlights with plastidip and so far, great matte look and no side effects. it does add a bit of thickness but it's robust and allows to peel off if you ever decide to go back to the all clear/chrome look.
Keep up the good work, Farukh. It's appreciated.
...and guess who has a TL that was built in August of 2003?
Also, not sure if anyone cares or has a fear of being able to revert to stock down the line, but I did this last set of headlights with plastidip and so far, great matte look and no side effects. it does add a bit of thickness but it's robust and allows to peel off if you ever decide to go back to the all clear/chrome look.
Joined: Sep 2008
Posts: 78,249
Likes: 20,202
I did a test and put in oven at 200 degrees for 10 minutes, just the bezels to bake the dip to ensure if there were any vapors created, they'd be released NOT in the headlight. When I took them out where I grabbed, my fingerprint did make a mark but the visible part remained intact. I'm almost 2 weeks in with driving with all the lights on in the mornings and a few times at night and so far so good.
I hope it lasts, I'm tired of opening them!
I hope it lasts, I'm tired of opening them!
Sup JnC looking to get my headlights done when you got the time.
Looking at just the following:
3G Type S headlights
USR clear diffusers
ZKW-R lenses
(Maybe Black Out V2?)
If I opt for the USR clear diffusers, then what else would be different if I also asked for black out V2? (since the diffuser would be switched already) I'm a newbie, so thanks in advance for fielding my questions haha. Would you also mind PMing me a price for all of it? I have an 07TLS and would want to do the core exchange program.
Thx!
Looking at just the following:
3G Type S headlights
USR clear diffusers
ZKW-R lenses
(Maybe Black Out V2?)
If I opt for the USR clear diffusers, then what else would be different if I also asked for black out V2? (since the diffuser would be switched already) I'm a newbie, so thanks in advance for fielding my questions haha. Would you also mind PMing me a price for all of it? I have an 07TLS and would want to do the core exchange program.
Thx!
