I bought a Audi A4 Headlamp along time ago hoping to do a custom setup but never got around to it. I also had an extra 2010 G37 Sedan headlight sitting in my kitchen that I had started to paint so I decided to try to come up with a way to custom mount some leds in the headlight. Since I have Solidworks (3D modeling) and a 3D (plastic) printer at work I decided to design a sleek housing to hold the leds to see how it would look.

First I laid down some tape to get the overall shape of where I wanted to mount the led housing. Then I scanned the shape into solidworks and started to model the housing shape. Once finished I printed it out and tested fitted it. Overall I think a did a good job on how the leds mount inside the housing but I found some fitment issues that I need to address once it went inside the headlight. I need to account for the angles and overhang of the headlight features so it can sit more flush. Here are some pictures let me know what you think? Nice or rice?

 

Interesting.. in for the finished pics!

 

In for the final as well.

 

NICE!!

upload pic we are eager to find out

 

I wish I had a 3d printer. Solidworks isn't as much fun when you can't print out anything besides 3 view drawings. Looks nice and clean right now, hopefully it looks even better on the car.

 

Looks nice, jus wondering how they look like when there on now.

 

Concept is great. As with you, I'm not sure how the fitment will be. Although it will be a clean job, it may not flow with the design and lines of the headlights.

My opinion is, if you can fabricate something that goes along the top curvature of the headlight, that would be nice.

 

Looks good! I think the inside corner should be more contoured, like how you have the outside corner. I can't wait to see the final results!

 

Nice! In for final pics

 

Yes I have some changes that I need to make to the overal shape so it can fit perfectly in the housing. I couldn't account for all the contours in my initial design, now that I have a prototype I can do allot more since I see how it mates up to the headlight.

 

Can't wait to see these fired up!

 

Which LED's are you using?

 

Ones from a Audi a4 (Osram advanced topleds with lens and heat sinks)

 

Where did you purchase them?

 

Def in for final pics!