First you have to find all of the parts; the headlight was found on a fleamarket and the base was extracted from an old desk lamp. It's basically a very simple job of painting the headlight and buffing all the chrome parts with some silver paper and cola (that really works, you know!).
Afterwards you only have to connect the 2 parts and add some electronic components and wires. It's just that easy!
List of parts:
-base of desk lamp
-transformer (not the robot kind, just a voltage supply)
-halogen replacement base
For the paint job you'll need:
Let's get started!
Step 1: Cleaning All the Parts
I did this with an angle grinder and sand paper. Just do it careful, because ones you shave it off, you can't put it back!
After the grinding off the lamp, I'll start prepping this for painting. Since the surface is already nice and course (for the paint to adhere better to the metal) I only had to clean off the dust and use some soap to remove residual oil from, for example, touching the lamp (those are bad for your paint layer).
While I let the headlight dry in the sun, I start with the cleaning of the chrome parts. This is done by pouring cola over the affected area and rubbing it consequently with the silver paper (use the shiny side). After a few rubbings the chrome will almost look as new!
For more information on that technique, visit this instructable: Chrome polishing - mythbusters style
Step 2: Painting the Headlight
After half an hour you can return to the lamp and start spraying a thin layer of metal paint on top of the primer. Again take it slow and wait for the paint to dry, which is, as the saying goes, very boring!
When the first layer is dry start with the second layer and repeat these steps until you have a nice and even layer of paint on that headlight.
Don't worry if the finishing layer has some small bumps, we'll get to that in the next step!
Step 3: Making It Shiny
So I started putting on some polishing wax and scrubbing it with a normal cloth. I repeated the adding polishing wax and scrubbing till the lamp's surface was becoming shiny and smooth.
Off course polishing wax can still be too course for making it as shiny as your car. So I started using car wax. This will partly fill the poreus surface of the paint and increase the reflectivity, which means make it more shiny! Do the same steps as before but this time with the car wax. Keep going and it will look like a freshly painted car!
Step 4: Start Working on the Electronics
Then I looked at the lamp inside the headlight. This is a car light and it needs a lot of amperes! So I started off with making my own replacement lamp. Take the old lamp and break off the glass bulb (be careful and watch out for sharp edges).
Next step is to drill out the base of this lamp till you can fit a halogen lamp base in it. I glued this in with some temperature resistant-glue and placed it so that a small 25W halogen lamp would fit inside of the headlight. Now your lamp should be finished!
Next step is adding a cool chrome light switch. In my lamp there was already a hole with just the right size to add my switch. If it hasn't got a hole with the right size, you'll have to drill a hole in it before you start painting the lamp.
Step 5: Connecting the Headlight With the Base
I increased the surface area of this socket by adding some clip ring. It's not really necessary, but it makes the construction somewhat more sturdy.
After screwing the lamp foot into the base, you should be still able to swivel the headlight with it's own mechanism. Also you should pull the wires through the lamp base and lead them inside the headlight. Now all the wires are in the right place and you can start soldering them together. Use some shrink wrap to insulate them because otherwise they might cause a short circuit.
Take a 12V transformer (normal supply) and attach it to your circuit, try out the switch and your lamp should start working. If not, check your circuit to see if everything is connected in the right way (voltmeter).
Step 6: Put It All Together and Enjoy!
If you have any questions, feel free to ask.