G28 - Simple Mans, Simple REDO of an G28 LP640

[autopro]

Awesome work once again buddy

[Simple Man]

Side markers - thank to Auto Pro for the picture of his fender, worth a thousand words 

Used a mini router.  Might add material to the inside of the fender and router more material off, to recess the fixture a little more. 

passenger side next

[Simple Man]

more fiber glass on passenger headlight surround, pretty close

Having taken the bumper and headlights on and off the car numerous times, weld nuts were added.  Really speeds up removal of head light assembly.

Have to adjust the height of bumper on the passenger side by about 1/4.

Using rubber washers to span the void between the frame and bumper.  Will use weld nuts on frame at bumper attachment points.

[AdrianBurton]

Just looked at the pics of the wall.... I didnt notice any kind of drainage behind it

1.5 inch crushed rock

Ok, I just saw it in the base not behind it

[Simple Man]

Just looked at the pics of the wall.... I didnt notice any kind of drainage behind it

1.5 inch crushed rock

[AdrianBurton]

Just looked at the pics of the wall.... I didnt notice any kind of drainage behind it

[Simple Man]

Nice work, now your headlights will have the proper gap all around.

Thanks !! they will be close enough for now 

[autopro]

Nice work, now your headlights will have the proper gap all around.

[Simple Man]

Happy 4th!! 

More of the same on the REDO.

Passenger side - A little different.  Added 6 - 1.5  layers on the backside, then grind on the top to bring the surface level with the head light.

Up higher on the headlight opposite problem added 3 - 1.5 layers.

Adding 4  - 1.5 layer to backside.... hope this will be the last.

Wall in between    glad when it is done to much like real work

[Simple Man]

Received a PM asking what parts I used for my headlights

Amber Lens - tired a fiero lens but melted it to much, So bought  a VW Golf Jetta Mk3 amber euri E code front bumper turn light. Thanks String

Amber fixture - 98-01 passat front fender side marker light - thanks Auto pro

Small round lens - used a test tube 20 x 150mm - thanks Murci Me and a t10 fixture and an amber LED - thanks  USMC butler

Big projector -2x 3.0" H1 Bi-Xenon Projector Lens For Custom Headlights HID Conversion Retrofit  - ebay seller motoringmax (186187)

Small projector - HELLA H13090611 Micro DE Series and hella bracket 8HG 153.152-001 bracket that fit the fixture

Morimoto Elite HID Kit - ebay seller Hid IllusionZ - would have used LED but already purchased

[Simple Man]

Drivers side pretty close.  On to the passenger side.

Thanks Murci Me for the guidance on dimensions

[Simple Man]

Needed to fix the gap between the fender and headlight. 

Added 2 layers of 1.5 to the back side.  Sand.  Then added 2 layers of 1.5 to the front.  Sand Then 2 layers of 1.5 to the back side.

Added another bracket for an attachment point, to the fender.

Worked on repairing a retaining wall while waiting for the fiber glass to set up.  55 -  63 lb blocks kicked my a$$!

[Simple Man]

But wait there is more... 

The headlight needs to be adjusted up as the fender sticks up about 1/4. 

or the fender needs to be taken down or a combination of both

[Simple Man]

Looking at a Murcielago hood and headlight alignment.  It appears the glass lines up with the end of the hood.

Mine appears to off by 1/4 inch.

The gap between the hood and the bumper is good. So probably move the headlight up 1/4, to fix this

[Simple Man]

I moved the upper fender attachment points in by about a 1/4 of and inch.