G28 - Simple Mans, Simple REDO of an G28 LP640

[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.

 

[Simple Man]

The front bumper looks great, it really changes the whole look of the car.

Thanks!  I think it looks great!!

[autopro]

The front bumper looks great, it really changes the whole look of the car.

[Simple Man]

Mounting the Murci-Me front bumper went pretty smoothly.

Added a little bit bigger flange to the bumper

With everything bolted up, some fiberglass work needed.  The way it is attached the REDO is flush with the MM bumper.

Will adjust the bolt hole in, and see if the gaps decrease.  Probably will, but then will have to add fiberglass to the outside edge of the REDO so it is flush with the bumper.

[Simple Man]

Sometimes the excitement  of the build is over whelming ....

For the E brake system, made a bracket that will be welded to the side of the cradle. 

Final one will be 1-2 inches off of the cradle, or not...

Then measure for the cables so they can be ordered.

[Simple Man]

So after milking fathers day for as much as I could..... 

I worked on attachment points for the bumper to fender area. 

made some metal brackets, welded some nuts to them,  This way the bumper can be bolted from the bottom once the headlights are in.  used  3m 08115 will fiber glass in later.

The brackets are about 1/8 inch up from the edge of the fender, will use rubber washers to make up the difference.

Might add as 1/2 tube/bar to the frame and weld to the brackets, if needed 

[Simple Man]

Nice work fella, I'll be stealing some of your learnings for my project. This is the beauty of sharing details like this with others, we can all learn and better our builds!!!  Thank You!!!

I try to keep a pretty detailed build thread, so glad you can gleam some ideas.  Its not like we are protecting our daughters from a loser boy friend 

So it is nice when folks show how they did it, not just I did it. 

[Purple LP670 SV]

Nice work fella, I'll be stealing some of your learnings for my project. This is the beauty of sharing details like this with others, we can all learn and better our builds!!!  Thank You!!!