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

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  • Hi folks,




    Welcome to a little R & D ........... and a little something else !

    Still working at it Jim Still trying my utmost to make these available by the end of the year mate ......... there's a long way to go yet, and many other things to get ready as well. But I think we'll manage it. I'm OK for parts at the moment mate ......... thanks for the offer though. Still trying to get my money back from that 'blade adaptor' fiasco ! Looks like I'll have to fabricate an adaptor for the 'adaptor' to make it work !


    Prototyping on the headlight assemblies is going well, but I'm also having to organise a proper workshop. I'm pretty much sorted with all the tooling, and I'm currently sorting out my work environment. To manufacture headlight parts effectively I think you have to also work effectively, which means organising your work-flow.

    Currently my workshop is in total disarray as can been seen in the following picture. Resins, silicon's, plastics and electronics have made way for lumber and sheets of MDF ! The price of lumber over here is astonishing ! so much so, I'm having to travel far and wide to purchase raw lumber just to keep the costs down, buying from a builders merchant means it's raw lumber so you have to plane it yourself. You can buy 'Planed All Round' in places like 'MrBrico' ( B&Q type places ), but at €24.00 per 2.5mtr, my workbenches would cost about €400 each ! So I'm doing it the old fashioned way for a fraction of the cost >>







    Once the 2nd workbench was completed and with the aid of my other workbench I completed last year, I could start on making yet another machine support. With all these extra machines that I've bought recently, I need to position these machines in such a way that it'll be an easy process of moulding/forming, cutting/trimming and then the assembly of the headlight units ........ moving from one machine to the next without too much disruption will undoubtedly make the entire process much quicker, thus more effective ....... and not forgetting, much safer ! As all these machines will take a finger off in no time ! >>







    While those types of things are happening during daylight hours, when I can fire-up various machines, I'm also still learning 'Blender 3D', so, very early in the mornings or in the evenings after a day in the workshop. There's only three other people that live in this entire street, but that's no reason to be making noise at 10:00 pm, specially at this time of year when everyone sleeps with their windows open.


    It's all very well producing technical drawings of your concepts on paper, but that's not very helpful for potential clients and customers .......... I think it's nice for people to see your concept and visualise what the finished product will look like when complete ........ it's how I see it in my head basically. Learning how to use 3D computer software isn't as easy as it looks, I'm having to familiarise myself with 'Solid surface modelling', mesh 'Topology', 'Rendering', 'Fresnel', 'Index Of Refraction', 'MatCaps' and a whole pile of other new words ! ........ It's fascinating stuff !







    As good as the headlight cover looks now, it's still far from being bang on ........ I have way too many polygons constructing the surface of the cover, and I'm struggling big time designing the twin holes in the cover. Every attempt I've had so far has had the holes being deformed when I apply the smooth modifier


    I try to put at least a couple of hours in every day with Blender 3D, mastering these techniques I think has a major part to play in product prototyping, so is a must if you're serious about product design and new concepts.


    Click here to see my very first attempt at 'Blender 3D' on this project ( toward the bottom of the page ) > http://www.vwt4forum.co.uk/showthrea...99#post2809799


    I also posted a short animated clip of the prototype headlight bracket ( modules ) at the time on YouTube >





    The animation was also done with Blender 3D ........... that's sure to come in handy when I begin to advertise the T4 Quad Headlight system to the world !








    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


    • Got to admire your dedication there mate, top marks.

      Comment


      • Thanks mate !

        I've also got a very big surprise for the lovers of the more contemporary look, yet functional headlight designs in store ! A style that some people may think that's not really suited for the T4 ......... but I think will work very well, from an aesthetic point of view.

        More on that at a later date



        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


        • Awesome work Turk! Will these be for the short or long nose?

          Sent from my SM-J710K using Just T4s

          Comment


          • Hi Bayerische,

            The pictures above are for the short nose T4 mate ......... and mostly concerning the 'Basic' Classic version of the quad headlights. I'm still working on the long nose version and only got to the mould making stage of the long nose. A very different approach will be needed for the long nose version of the quad headlights, firstly, because of the more curved nature of the long nose' front end and the Hella headlight units I'm using are much larger as you can see in the pic below >>




            One of the issues I'm encountering is, there isn't a single flat straight edge anywhere on these, so designing the moulds is proving to be quite difficult.


            It's quite a process creating moulds for resin casting, as an example, here's a shot of the template process ......... >>




            There's also quite a bit more information on the long nose quad headlights a few pages back in this thread.





            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 again,


              Been playing around with Blender 3D this evening, sussed out a method for cutting holes out of a mesh without distorting the circles too much, got the holes in the wrong place, and the diameter wrong as well ! ......... but at least this gives me an idea of what the headlight covers should look like. Strictly speaking the topology isn't quite correct, but at least the shading came out OK


              I couldn't quite get the yellow gloss shading to work right ........ hope a blue headlight cover is OK Jim ? >>









              PS; If anyone here is familiar with Blender 3D .......... I could do with some help !








              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


              • Turk techniques workshop is coming along nicely!!
                I wish the boss would let me have a workshop like that!!

                Comment


                • Originally posted by Greeny gtc View Post
                  Turk techniques workshop is coming along nicely!!
                  I wish the boss would let me have a workshop like that!!



                  Places to hide from er in doors ! You too could have a workshop like that ........ just convert your lounge into a workshop like I did !

                  I could do with 2 workshops actually ......... most of time it's way too dusty in here to work with plastics, you wouldn't believe how irritating static elec is !





                  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 converting the lounge would go down like a sack of lead balloons!!
                    She ain't really happy I have a lock up for storing all those important car parts I can't live without!!

                    Comment


                    • Originally posted by Greeny gtc View Post
                      I think converting the lounge would go down like a sack of lead balloons!!
                      She ain't really happy I have a lock up for storing all those important car parts I can't live without!!

                      I feel for you mate

                      A man should have his own space ............




                      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


                      • Space ah I remember that the place I went soon could listen to my tinnitus!!!! As lapsed to the tinnitus being drowned out by the boss and her assistants!!!!!

                        Comment


                        • As opposed to not lapsed.....

                          Comment


                          • Thanks for the elaborate answer Turk. I will be following and if it ever happens for us long nose guys Im in for sure.

                            Sent from my SM-J710K using Just T4s

                            Comment


                            • Originally posted by BayerischeT4 View Post
                              Thanks for the elaborate answer Turk. I will be following and if it ever happens for us long nose guys Im in for sure.

                              Sent from my SM-J710K using Just T4s

                              'IF' !? .......... It's sure to happen my friend

                              I've got a long nose as well ! >>




                              LHD German import.
                              151 bhp MultiVan



                              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


                              • Nice rides!

                                Sent from my SM-J710K using Just T4s

                                Comment

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