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

[TURK]

Just a quick update folks to let you all know where we are.


Carrying on from the vacuum formed 3mm ABS headlight mounting bracket, is the 'profiling' stage. Basically, cutting the final part down, drilling the holes, cutting the headlight apertures and then the final trimming around the base. Sounds easy ................. but from what I've already experienced, this is by far the hardest part. So many different tools and processes involved also makes this quite a lengthy procedure, it's part of my workflow that I'm still working on ................ what to do next and how to do it correctly. And safely, as now I'm having to use high speed cutting tools, routers and various cutting mills.




The first part is to cut away the waste material, cutting plastics isn't always as straight forward as it seems, as the incorrect type of blade combined with too high a cutting speed tends to fuse ( or melt ) the plastic sheet back together again behind the cutting blade. But this is possible with correct blade and speed set on a bandsaw >>







A quick test to see if the forth mounting point for the fixing bolt will work. Looks OK at the moment >>







Next up is to cut the base off ............... here is where the problems began ! Because my part is now 2mm bigger all the way round, the part doesn't fit in my original cutting jig >>







I worked out last time that greater accuracy in cutting the base off was achievable only from inside the part, with the part upside down, so I want to continue using this method.


My original cutting jig >>









So I need to router out a section of the jig down 2mm to make the jig slightly larger >>







As I have a number of rotary tools, like Dremels, routers and milling machine ................... wouldn't it be great if I could use standardised router and cutting bits in all those machines, it would certainly negate buying different sets of bits for each machine wouldn't it !? The 'Proxxon' milling machine on the left runs between 900rpm - 6,000rpm and the Makita trimmer runs between 10,000rpm - 30,000rpm so that means I could choose which machine to use for any given task or material used.


Not on your life ! every single machine has a different adaptor ! nothing fits, nothing' interchangeable


The router bit set I have are for 8mm shanks ( 8mm and 12mm being the European standard sizes ) because that' the size of the adaptors ( collets ), which also means I can't shop for router bits in the UK as they're 'imperial' ! ( 1/2" and 1/4" ). So now I'm on the hunt for a 6.35mm ( 1/4" ) adaptor ! >>







Here's one method I could use ................... but you certainly wouldn't use this tool and router bit free hand ! even looks dangerous ! >>







So now I'm having to build a router table




Anyone know of a decent supplier in the UK that can supply spiral upcut router bits ? as after spending all day searching on the Internet yesterday ( and part of last night ) I'm getting very tired of looking ! I would prefer to order router bits from the UK as the prices over here for tools are extortionate. Sometimes as much as €90 for a basic router bit that's around £30 in the UK.










TURK

[Mr Nozzle]

Thanks for the update mate. I did a bit of internetting whilst at work and found these http://www.ebay.co.uk/itm/Trend-HSS-...26.m2548.l4275
I'm not sure if you've seen them or even if it's what you're after to be honest? :-)

[Greeny gtc]

Hat is doffd again Turk!!!

Sent from my SM-G930F using Just T4s

[TURK]

Thanks for the update mate. I did a bit of internetting whilst at work and found these http://www.ebay.co.uk/itm/Trend-HSS-...26.m2548.l4275
I'm not sure if you've seen them or even if it's what you're after to be honest? :-)

Thanks Mr Nozzle Yup, that's the sort of thing ...................... but did you notice the error in the ad ?
And that's another problem I'm encountering with most advertisements, it states that it's 8mm shank .............. equivalent to 1/4"
No it's not ! unfortunately most people get taken in by this ( I've fallen for it a few times already ! ) 1/4" equals 6.35mm ! so you end up buying things that don't fit.
Why can't these suppliers get things right ! these can be very costly mistakes




TURK

[TURK]

Hat is doffd again Turk!!!

Thanks mate

Unfortunately this is where progress slows to a crawl on the headlight parts, but it's all part and parcel of tooling up a workshop I guess. You could try and bodge things up and find work-arounds, but that' not the way I work, I'm after precision and for that you really do need the correct tools .................. and good quality ones at that.




TURK

[Greeny gtc]

Right sod it I can resist no more!!
Put my name on the pre-order list please.
Ness is a 2002 short nose who already has the led devil eye headlights.

Sent from my SM-G930F using Just T4s

[TURK]

Right sod it I can resist no more!!
Put my name on the pre-order list please.
Ness is a 2002 short nose who already has the led devil eye headlights.

Consider it done Greeny !
You would of saved up quite a few bob by the time the lights are ready !



TURK

[Greeny gtc]

Consider it done Greeny ! [ATTACH=CONFIG]5815[/ATTACH]
You would of saved up quite a few bob by the time the lights are ready !



TURK

I didnt fit them they were on when I got her.
But I do like to be different so Turk tec rules!!

Sent from my SM-G930F using Just T4s

[TURK]

Yeah, I remember seeing Ness in you build thread, aren't those the Audi type headlights without the bulge on the side ? Been told they fail the MOT test as the indicator can't be seen from the side. You had any issues with that ?

Not only are you going to be different Greeny .................... but you'll be able to see where you're going at night
I took my Audi LED type headlights off and replaced them with the OE headlights, I just got tired of tiptoeing around at night, I kid you not ............... sometimes I was down to mere 30 odd MPH, as I just couldn't see the road ahead.

Anyway mate, check the previous page ....... you're at #116




TURK

[Greeny gtc]

Yea audi drl devil they have a number of names.
I have led repeaters in the wings so no issue with mot.
When I got Ness i really didn't know what people were complaining about as mine are quite good but further inspection I have the loom upgrade and night breaker lamps in them.

Sent from my SM-G930F using Just T4s

[S49]

The loom mod made a light and day difference to our corrado, cuts out any resistance of loom or switch. Will do van as a matter of course

[Grubb05]

I'd be better off strapping a couple of torches on the front then the old original headlights

Sent from my LG-H870 using Just T4s

[TURK]

The loom upgrade will always be a major improvement, particularly on vans that suffer major voltage drop, which is most T4's. Caravelle's and MultiVan's not so much, as the headlight wiring system is slightly different. But you can't get away from the fact the OE oblong headlights on the T4 was a very poor design to begin with. Greeny' DRL type headlights are probably made by JK being the round units, so not as poor as the ones I have, the DEPO ones I have an oblong 2" x 4" high beam that is appalling !

You can't beat a parabolic shape for reflecting light into a tight beam pattern .................... that's why all hand torches are round and not square, or worst still, oblong !




TURK

[TURK]

For anybody else who is thinking about buying a set of those cheap drl type headlights, have a look at some early tests I did with them. The markings on the workshop wall are in accordance with the MOT test, and so is the distance of the front of the vehicle.


This is them in Low beam. you'll also notice that the 'kick-up' required in the UK isn't on the left hand side of the road, but toward the oncoming traffic on the right ! so the low beam units have to be adjusted downward so as to not blind oncoming traffic. As far as I know they were never made for the UK market. The result is, there is practically no light on the left hand side of the road, or where the pavement would be >>





High beams aren't that much better ....... the beam pattern is pretty much all over the place, with no definite beam pattern ! >>






And now compare the above images to the Hella Quads that I'm currently working on. Low beams with 15% kick-up on the left where it should be >>






And now the Hella high beams ........ a definite narrow beam with a nicely defined focal point, you'll also notice just how much higher the beam is, which means greater distance >>





I should point out at this stage that those simple tests were conducted without a headlight upgrade wiring loom. At the time I was getting about 11.6 volts at my lights .......... with my new quad headlight wiring loom I should be getting closer to 14.4 volts. So they can be better still. Also, my quad system will have all four low beams and high beams ON in high beam, so you'll see the sides of the road as well. More tests will follow guys once I get passed my headlight bracket design.

Getting back the the dreaded drl type headlights ..................... you can polish a turd ................. but a turd will always be a turd !




TURK

[S49]

Very impressive mate.