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T4 Quad Headlight Project .......... latest update

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  • We run exactly the same setup as the forum so can't see how ours can be an issue, I'd say it something your end.



    Just to show pics haven't worked on there either


    Comment


    • Funnily enough Turk I actually nearly started a thread asking you about this last night, but didn't as I thought it might just have been me being an idiot, I often struggle to see your photos, I took a screen grab here's what I see for a lot of your photos not all but a lot, I originally thought it was your old ones but then these new ones did it too. Odd!


      Sent from my iPad using Just T4s

      Comment


      • How does the thread look on your desk top PC Dan ?

        Images showing very clearly I suspect !




        TURK
        Yeah, baby ! ........ new Multivan 151bhp AHY 'BigBlue' ; ) >> http://www.vwt4forum.co.uk/showthread.php?t=1023689
        And ......... Lulu, T4 2.5 TDi short nose 126bhp > http://www.vwt4forum.co.uk/showthread.php?t=276554
        The T4 Quad Headlight Project > http://www.vwt4forum.co.uk/showthread.php?t=249064

        Comment


        • I think I know what the problem is Ricky ........

          Take a look at this > http://just-t4s.co.uk/showthread.php...test-my-theory




          TURK
          Yeah, baby ! ........ new Multivan 151bhp AHY 'BigBlue' ; ) >> http://www.vwt4forum.co.uk/showthread.php?t=1023689
          And ......... Lulu, T4 2.5 TDi short nose 126bhp > http://www.vwt4forum.co.uk/showthread.php?t=276554
          The T4 Quad Headlight Project > http://www.vwt4forum.co.uk/showthread.php?t=249064

          Comment


          • Hi Folks,

            Now that we all know that my images or this site are not to blame for people not being able to view images ......... I'll carry on as I have done for the last few years !


            A long overdue update on the Quad Headlight Project I'm sure you'd agree ........ so, lets jump right in !

            It seems that as soon as I've found a solution to one problem, that another problem turns up ! Engineering in any guise is problem solving, I guess that's why I love this sort of thing so much


            Anyway, problem number one .......... probably the most difficult one as one mistake on this part would render my existing tooling plugs useless ! You'll see in the image below that I've indicated by way of a small red arrow, the area that needs to be modified. That tiny pilot hole indicates where the forth mounting bolt should be >>






            As each Hella steel mounting frame has four points for mounting into your headlight assembly, you need to be able to secure all four of these bolts in order to get a decent fixation, anything less, and it could result in vibration of the final assembly. As you can see in the picture below, the middle fixing point ( 8mm hole ) doesn't line up with the headlight mounting bracket. That's because of the draft angle that' necessary for the vacuum formed part >>






            My solution was this ........ first I would transfer those measurements onto my tooling plug, and as these prototype parts have rounded corners that's quite difficult ! So a little ingenuity is required. I struck upon the idea of using a 'Contour Gauge Duplicator', like the ones flooring specialists use when installing laminate flooring around door thresholds. - Notice how I've left one pin sticking out to indicate where the centre of the hole will be >>






            Then you just transfer the gauge over to your tooling plug ( or work piece ) ......... simples ! >>






            The rest of the operation turned out to be quite a set up, last thing you need here is for the work piece to move. My milling machine with it's compound table is far too small for a work piece as large as this, so I have to make do with my pillar drill. You'll also see in the picture there, the sanding spindle I made specifically for this task >>






            Once you have your angles correct, with the aid of your jig ....... you can begin to gently sand out a groove in the resin >>






            As it turned out, this worked flawlessly ........ but there is an issue ! Right at the footing of that groove, there is a step up that I couldn't get to because of the angles, particularly the angle of the spindle. That area, for obvious reasons needs to be a dead flat surface as it's where the head of the bolt will be >>






            Even by glueing a small circle of sand paper on the end of the spindle wasn't working >>






            So, I came up with this ....... It's basically a cut down 6 inch nail, with a filed down cross-hair in the head of the nail. The filed down cross-hairs, act as a cutting edge ....... it worked very well actually As the diameter of the nail is smaller than the diameter of the sanding spindle, it allowed me to get into that more acute corner by increasing the angle of attack >>






            Problem number two, also solved T: ........ This could so easily have been so straight forward, just unscrew a screw !!! but it simply just spun ! :* Reason being, some nugget decided to use 'riv-nuts' on the platten of this vacuum forming machine. Bad design ! It stands to reason that if you put a round riv-nut in a round hole, in time the riv-nut will simply spin and make the connection useless ....... that's why I hate them and never use em !


            So after taking my vacuum forming machine apart to gain access to the underside, I put some 'JB Weld' or better known as 'Liquid Metal on the riv-nuts to secure them in place. Reassembled vacuum machine, now all is well again >>






            And here's the reason why I need secured riv-nuts ......... You'll notice in the YouTube video how the operator has his vacuum forming plug ( the car ) mounted onto a base-board ........ this also happens to be the machine I have Rasp: >>






            Now onto my other problem, still needs to be resolved After spending literally weeks trying to get hole of some barbed brass inserts, I seem to have hit upon another issue. The manufacturers recommend a 6.5mm drill bit for easy installation of the inserts ......... definitely not ! 6.5mm isn't big enough and 7mm is too big ! as you can see in the picture the insert simply falls into the 7mm hole. The other thing is, you can't buy 6.5mm drill bits with the points on them, they just don't make them. >>






            Again, my milling machine is far too small to accommodate a work piece as large as this, so I'll have to use my pillar drill. Only very very expensive engineers pillar drills will run true, most if not all the others will suffer from 'Run-Out', basically there's a slight wobble as they spin the drill bit ........ but this could work in my favour ! It stands to reason that if a 6.5mm drill bit is slightly too small, with the 'run-out' you would end up with a hole slightly larger than 6.5mm, right !
            So I spent a few hours testing my pillar drill to see just how much 'run-out' my machine suffered from. Here I'm using a metric 'Dial Indicator' that measures in 10 micron increments, if you don't know, there are 1,000 Microns to 1mm. My gauge is indicating that the 'run-out' ( wobble ) is 12 Microns, that equates to 0.012mm of movement. That's not bad when you consider that the thickness of the average human hair is 0.08mm ( or 80 Microns ) >>






            So, did it work ? ....... nope ! still way too tight After banging away with my pin hammer I had to use my 16oz hammer to try and insert the inserts, to the point of almost cracking my resin tooling plug. In fact, the brass insert cracked ! Now I'm really stuck, I can't go any further in, nor can I remove it !

            Looks like I'll have to grind the insert down >>







            Just as a footnote ........ I wouldn't of believed that 6.8mm ( or 0.26" Imperial ) drill bits were available !

            So I've ordered some ....... hopefully I should get them in a couple of weeks, until then the project is on hold yet again ! :*






            TURK
            Yeah, baby ! ........ new Multivan 151bhp AHY 'BigBlue' ; ) >> http://www.vwt4forum.co.uk/showthread.php?t=1023689
            And ......... Lulu, T4 2.5 TDi short nose 126bhp > http://www.vwt4forum.co.uk/showthread.php?t=276554
            The T4 Quad Headlight Project > http://www.vwt4forum.co.uk/showthread.php?t=249064

            Comment


            • Getting there slowly but surely Turk. Don't envy you trying to work some of this stuff out!

              Comment


              • Originally posted by tallpaul View Post
                Getting there slowly but surely Turk. Don't envy you trying to work some of this stuff out!
                Thanks Paul, things may look a little deceiving as a thread sort of thing when just looking at pictures of the procedures ......... some people may even think that it's quite easy ! It's just a case of making a mould from your original drawings, whack a sheet of plastic on a vacuum forming machine that does the rest for you ......... and simply glue the bits together ! and voila, one headlight unit !

                And in a nutshell, that's more or less what it boils down to ...........

                By far the most difficult thing to do, to the point of being impossible, is having to deal with so called 'retailers' ! Selling products, materials and parts is what they're supposed to be doing, but they just don't seem to be interested ! I'm still trying to sort out the issue with the wrong part they sent me that I bought on the first of May, for my plastics cutting machine, they have sent me a replacement ( a few weeks ago ) .......... but that' exactly the same 'wrong part' that they sent the first time round ! I've been chasing them up ever since. Now they're ignoring my emails !

                What most of these companies do is, they tend to drag the situation with the intention that you will drop the issue as it's taking too long to sort, and with so much frustration on your part, you just want to see the back of it. At the end of the day, they have your money ....... and that's they main concern. 'Customer Service' are just two words that don't mean anything these days.


                As the short nose version of the quad headlights is on hold because of another issue ......... I can spend more time on developing the long nose version, so that's coming along just great




                TURK
                Yeah, baby ! ........ new Multivan 151bhp AHY 'BigBlue' ; ) >> http://www.vwt4forum.co.uk/showthread.php?t=1023689
                And ......... Lulu, T4 2.5 TDi short nose 126bhp > http://www.vwt4forum.co.uk/showthread.php?t=276554
                The T4 Quad Headlight Project > http://www.vwt4forum.co.uk/showthread.php?t=249064

                Comment


                • Keep it going mate, most companies just piss you about these days, be nice to see either set up and running 👍

                  Sell my T4 ? I'd rather stick wasps up my butt !!!

                  Comment


                  • Hi mate,

                    Yeah, as frustrating as it is waiting for parts, spares and consumables, I've always got the other prototype to work on, the long nose version is coming along nicely now. For a long time there, I was doubting that the actual design I wanted wasn't going to work ......... the large Hella 100mm 'outboard' unit and the smaller 90mm unit ( high beam ) inboard. Because of the slanted OE headlights and the very rounded front end of the long nose version, I don't think that twin 90mm units side-by-side would of looked too pleasing to the eye. Wouldn't of looked right in my mind. At least now I know it's possible ...... just as well really, as I've already bought the stock ! I had to really as at the time, I had to put together a rather large order so Hella UK could give me a better deal on the headlight units, so I bought a few dozen pairs. And I had to buy quite a few sets of headlight retainers ....... I've got boxes of em !

                    Been at it all night again ....... just stepped out the workshop ! Finished with the long nose prototype mock-up for now, now I've got to concentrate on building another work bench. With all these new machines I've got to workout a 'production line' sort of thing. You have to kind of work out a work flow, forming, sanding, cutting, assembling and glueing the assemblies together .......... it's going to be like a little factory !

                    My 'Design Studio' is upstairs in a dust free environment, where all my computers and printers are set up, so things are really taking shape.


                    Vorsprung Durch Turknik !




                    TURK
                    Yeah, baby ! ........ new Multivan 151bhp AHY 'BigBlue' ; ) >> http://www.vwt4forum.co.uk/showthread.php?t=1023689
                    And ......... Lulu, T4 2.5 TDi short nose 126bhp > http://www.vwt4forum.co.uk/showthread.php?t=276554
                    The T4 Quad Headlight Project > http://www.vwt4forum.co.uk/showthread.php?t=249064

                    Comment


                    • Fair play that's some sort of work your putting into that.

                      Comment


                      • Vorsprung Dutch Turknik. Love that.
                        Me cago en la madre que te parió!

                        Comment


                        • Yeah, one of the lads on the other forum thought of that .......... I quite liked it so decided to use it !

                          Has a nice ring to it.




                          TURK
                          Yeah, baby ! ........ new Multivan 151bhp AHY 'BigBlue' ; ) >> http://www.vwt4forum.co.uk/showthread.php?t=1023689
                          And ......... Lulu, T4 2.5 TDi short nose 126bhp > http://www.vwt4forum.co.uk/showthread.php?t=276554
                          The T4 Quad Headlight Project > http://www.vwt4forum.co.uk/showthread.php?t=249064

                          Comment


                          • Sure does.
                            used to be a dog walker years ago with "four sprung paw technique" on her van. Cool.
                            Me cago en la madre que te parió!

                            Comment


                            • Morning all,


                              All quite on the western front ( and in central France ! ) ......... so I thought I would post-up the very latest 'Pre-Order List', as I've had a few more orders.

                              Feel free to add you your names if you're interested in purchasing a set of these lights when full production begins, which isn't going be too far away now.




                              T4 Quad Headlight Pre-Order List



                              Order No Forum Member Date of Order Short Nose Year Long Nose Year
                              000 ProtoType [ type VI ] ..... mine ! - Y 2003 Y 1999
                              001 Camperwagen 29/01/2013 ? ? ? ?
                              002 JB Fab 29/01/2013 ? ? ? ?
                              003 Russ Dylan 29/01/2013 Y 1996 - -
                              004 Lord Farquad 30/01/2013 - - Y ?
                              005 slimjim 30/01/2013 Y 2000 - -
                              006 Steve Farries 30/01/2013 Y 1999 - -
                              007 AllTorgue 30/01/2013 ? ? ? ?
                              008 martbolton 30/01/2013 Y ? - -
                              009 HarryDubya 30/01/2013 Y 2003 - -
                              010 Vision Performance 30/01/2013 Y 2002 - -
                              011 PoeC 02/02/2013 Y 2002 - -
                              012 R19KY W 05/02/2013 Y 2003 - -
                              013 T-Licious 05/02/2013 Y 2002 - -
                              014 HillTopper 06/02/2013 Y 2002 - -
                              015 Paulm 07/02/2013 Y 2002 - -
                              016 elder81 07/02/2013 Y 2001 - -
                              017 jasibus 08/02/2013 Y 2003 - -
                              018 jerv1982 26/02/2013 Y 1998 - -
                              019 Clarkey 28/02/2013 Y 1998 - -
                              020 diviy 01/03/2013 Y 1997 - -
                              021 RichardU 01/03/2013 Y 2001 - -
                              022 ozymaster 03/03/2013 - - Y 2003
                              023 TouringMatt 04/03/2013 - - Y ?
                              024 Mark Freer 04/03/2013 Y 2001 - -
                              025 Amnesia180 05/03/2013 ? ? ? ?
                              026 windsurf-mac 17/03/2013 Y 2000 - -
                              027 Thejman 28/03/2013 Y 2001 - -
                              028 Spanners 10/04/2013 - - Y ?
                              029 KevanT 10/04/2013 Y ? - -
                              030 jerry75 22/04/2013 Y 1997 - -
                              031 jerry75 22/04/2013 Y 1994 - -
                              032 Hatman 22/04/2013 Y 1994 - -
                              033 T4 44ark 22/04/2013 Y 2001 - -
                              034 tony195950 22/04/2013 Y 2000 - -
                              035 Mike-S 22/04/2013 ? ? ? ?
                              036 Winchweight 27/04/2013 Y 2000 - -
                              037 Clunkey 27/04/2013 Y 2003 - -
                              038 daveporter40 29/04/2013 Y 2000 - -
                              039 Twister 01/05/2013 - - Y 2003
                              040 elmo 05/06/2013 Y 1999 - -
                              041 Brumski 07/06/2013 Y 2001 - -
                              042 t4mrs 16/06/2013 Y 2001 - -
                              043 MTCamper 23/06/2013 Y 2001 - -
                              044 Wonka 01/09/2013 Y 1999 - -
                              045 Koop 02/09/2013 Y 1995 - -
                              046 Gooson 02/09/2013 Y 2002 - -
                              047 Crewdub 21/09/2013 Y 2003 - -
                              048 Mat Rasky 13/10/2013 Y ? - -
                              049 Ian6xtreme 17/10/2013 Y 2001 - -
                              050 forestknights 18/10/2013 Y 1999 - -
                              051 G.U.B 21/11/2013 Y 1994 - -
                              052 edwarddog2000 21/11/2013 Y 1996 - -
                              053 Bigted 23/11/2013 Y 1998 - -
                              054 Helen00 26/11/2013 Y 1995 - -
                              055 Don Paul 30/11/2013 Y 1996 - -
                              056 Tony Hillyard 13/12/2013 ? ? ? ?
                              057 CarbonPhil 05/05/2014 Y 1998 - -
                              058 elmo2002 07/05/2014 ? ? ? ?
                              059 thorney 07/05/2014 Y 2002 - -
                              060 Bazpau4 18/05/2014 Y 2002 - -
                              061 ash.addy 20/07/2014 ? ? ? ?
                              062 camper chris 22/07/2014 Y 1996 - -
                              063 slamt4 27/07/2014 Y 1992 - -
                              064 familylugg 27/08/2014 - - Y 1996
                              065 bute555 12/01/2015 Y 2000 - -
                              066 Gazmataz 14/01/2015 Y 1998 - -
                              067 druggedonions 05/02/2015 - - Y ?
                              068 veedubadub 08/02/2015 - - Y 2003
                              069 bluethermal 27/06/2015 Y 1998 - -
                              070 D9lek 27/09/2015 Y 2002 - -
                              071 Lex Luther 08/10/2015 - - Y 1999
                              072 T4 Olly 09/10/2015 Y 1992 - -
                              073 Adam&Helen 11/10/2015 Y 2003 - -
                              074 oskins 14/11/2015 Y 1999 - -
                              075 Ballistix 14/11/2015 Y 1996 - -
                              076 T25T4Lvr 28/11/2015 Y 1993 - -
                              077 Eddierai 02/12/2015 Y 2000 - -
                              078 GazPlow 28/12/2015 Y 2002 - -
                              079 The-Fozzer 03/02/2016 Y 1999 - -
                              080 Robbbert 06/02/2016 - - Y 2001
                              081 PapaW 14/02/2016 Y 2002 - -
                              082 RedPedro 05/07/2016 Y 2003 - -
                              083 Perspextow 07/07/2016 Y 2002 - -
                              084 donecan 11/07/2016 Y 2003 - -
                              085 sfmerc 12/07/2016 Y 2002 - -
                              086 el-stig 20/09/2016 - - Y 2003
                              087 danpayneuk 13/11/2016 Y 2003 - -
                              088 HUDDERS 14/11/2016 Y 1998 - -
                              089 LawAnderson 14/11/2016 Y 1997 - -
                              090 TDItech 14/11/2016 Y 1993 - -
                              091 DAMIT 15/11/2016 Y 2001 - -
                              092 TallP@ul 16/11/2016 Y 2001 - -
                              093 Or_GazM 23/11/2016 Y 2000 - -
                              094 Lenster 25/11/2016 Y 2001 - -
                              095 Arkwright 10/12/2016 Y 2002 - -
                              096 JustinR 26/12/2016 Y 1999 - -
                              097 Snowrider 28/12/2016 Y 2001 - -
                              098 NoizBoi 12/01/2017 Y 2000 - -
                              099 arfur fox-acre 22/01/2017 Y 1998 - -
                              100 Jonnybigballs85 22/01/2017 Y 2000 - -
                              101 eejit 21/02/2017 - - Y 1998
                              102 eightball1977 28/02/2017 Y 1996 - -
                              103 b0z 04/03/2017 Y 2002 - -
                              104 jaymarley 05/03/2017 Y 2002 - -
                              105 Naith 06/03/2017 ? ? ? ?
                              106 Cpwood32 18/03/2017 Y 1998 - -
                              107 Fultonius 20/03/2017 Y 1998 - -
                              108 sancarlos 21/03/2017 Y 1997 - -
                              109 B a n 23/03/2017 Y 1999 - -
                              110 MrNozzle 02/05/2017 Y 2000 - -
                              111 Jed100 02/05/2017 Y 2003 - -
                              112 TomLiddle 27/06/2017 Y 2000 - -
                              113 Geodawg 29/06/2017 Y 2000 - -
                              114 mattmag 07/07/2017 Y 1998 - -
                              115 Could be you here ..... !


                              Don't feel you're signing your live's away here guy's, you can change your mind' anytime you see fit. It's not an official order ........ just an 'interest list'.



                              Thank you all for your continued support.



                              TURK
                              Yeah, baby ! ........ new Multivan 151bhp AHY 'BigBlue' ; ) >> http://www.vwt4forum.co.uk/showthread.php?t=1023689
                              And ......... Lulu, T4 2.5 TDi short nose 126bhp > http://www.vwt4forum.co.uk/showthread.php?t=276554
                              The T4 Quad Headlight Project > http://www.vwt4forum.co.uk/showthread.php?t=249064

                              Comment


                              • How are things going Turk?

                                Anything anyone can help with on parts supply?
                                BONGO FURY - 222bhp - 390lb/ft - 16.7064 1/4
                                Are you quick enough for the T17.club?

                                Comment

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