New Headlight Pods

[slomove]

Finally I got these Hella projector modules installed. Daytime running lights, side marker lights and turn signals are integrated. This was one of the more frustrating projects. Making the shells was easy enough (I have access to a 3D-printer) but the painting and epoxy clear coating almost killed me (had to do over 3 times...). I am quite happy with the result, even if the cosmetic finish was eventually so so.

 

http://lh6.ggpht.com/_242PlvPtVpE/Sza4Hv7FGTI/AAAAAAAABCM/uJF_Sy33yWQ/s1152/P1010648.JPG

 

http://lh4.ggpht.com/_242PlvPtVpE/Sza4D_sum7I/AAAAAAAABCA/2mtyjj93ebI/s1024/P1010644.JPG

 

More pictures here .

 

Gert

Edited December 27, 2009 by slomove

[snookwheel]

Wow!! Very nice. You built those pods yourself? That's talent! It looks real nice.

 

Scott

[TheDingo8MyBaby]

Gert,

 

Excellent work. Those look great and I'll bet they cut down the drag significantly.

 

What type of material did you use on the cases? I know some 3D printing materials can be sensitive to moisture. Also- it looks like you may have used some self tapping screws to hold the halves together? If so, I'd suggest using threaded inserts.

[Hank]

Love 'em!

[Boxologist]

looks awesome. how noticable is the directional/hazard when the headlight/projector is on?

[slomove]

Thanks for nice words, guys :seeya:

 

I have yet to see the turn signal at night myself. I looked up the brightest orange LED in 5mm dia. package that I could find but at 4,000 mcd they are still substantially less bright than e.g. the white ones at 18,000 mcd. That is maybe the reason the LED front turn signals are not really common yet on production cars.

 

 

On the plus side the projector low beams have a sharp cut-off and should not interfere too much with the turn signal. But I am already upgrading the upgrade and will look into real HID retrofit kits for the H9 bulbs in the projectors

 

For Dingo8: the shells are made from ABS on an FDM machine. It is not as strong as solid molded ABS (more like plywood) and a bit porous but surely waterproof. Actually I did use brass threaded inserts intended for wood. They needed some soldering iron help to mold into the ABS.

[s2k7]

Gert--- awesome pod you got!!

 

I found this - it's nice too, but I rather have one unit.

 

http://img63.imageshack.us/img63/1003/westfieldlights.jpg

[s2k7]

Here is another idea for pod

http://www.locostbuilders.co.uk/viewthread.php?tid=127994

[MightyMike]

Very nice! Is the bracketry new too?

[lancylad]

Beauty job.... where did you get those side mirrors and the mounting brackets? I promised the love of my life I wouldnt start the upgrade thing, now see what you've done....:drool:

[slomove]

Hi, not sure if you are still talking about my car or the Brit car with the double head lights.

 

Anyway, if it is about mine, the mirrors are bullet mirrors that I got from a friend. But you can find places to get a pair for $50 or less. I made the tripod from 5/16 x 1/4 aluminum tube bent to shape with an M6 stainless threaded rod inside. That way, I can attach it to the body as well as the mirrors with simple M6 nuts.

 

And yes, I made the headlight brackets from stainless tubing so that the cable is completely routed inside.

[lancylad]

Thanks, I did mean your car Slomove. They look awesome. Steve