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

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    Cheers for the update Turk. I like the design with the Frosties image - It'd be pretty cool driving up the M1 at night with other motorists thinking they're being chased by a pair of Tony the Tigers.! [emoji23] They're Lllllllllate ..... I mean Grrrrrreat! [emoji23][emoji23][emoji23]

    Keep us posted - "hats-off award" to you for the dedication. [emoji106]
    Last edited by Activ8; 29th April 2019, 09:16 AM.

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    • Some very cool pics there chap.

      I know it would be a ball ache but is it possible to polish the clear plastic back to a good shine?
      Just thinking that the webbing could be sanded/cut down and polished up, if it is going to be an issue long term?

      BONGO FURY - 222bhp - 390lb/ft - 16.7064 1/4
      Are you quick enough for the T17.club?

      Comment


      • Thanks guys.

        Lets hope they turn out to be Grrrrreat!


        Headlight covers all marked-up ready for the next stage >>

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        As there's another part to go inside the assembly for the clear cover version ( in front of the headlight mounting bracket ), I need a bit more space inside the assembly. One of the issues making these parts 'universal'! All this faffing about will pay off in the end though I think. So, after measuring everything again, I re-measured everything again! ( as you do ) and came to the conclusion that 4mm has to come off the bottom of the headlight mounting brackets. That should make the brackets sit a tad further in leaving me a little more room behind the covers >>

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        The next stage will be quite interesting, I can't wait for it actually, I've been 'collecting' various round containers for the past few months, supermarket shelves are a great resource for this, all sorts of different packaging! I do get stared at though ................. not the done thing measuring containers with callipers in a supermarket!

        But if I get caught and somebody asks what I'm doing, I've got my line ready .................... Just making sure it'll fit in my cupboard!






        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


        • Originally posted by slimjim View Post
          Some very cool pics there chap.

          I know it would be a ball ache but is it possible to polish the clear plastic back to a good shine?
          Just thinking that the webbing could be sanded/cut down and polished up, if it is going to be an issue long term?


          Hi Jim, and thanks mate.


          I'm working on the eradicating the webbing all together mate, a malformed part isn't a good part in my book. As extruded plastic sheets are 'Hygroscopic', basically they are prone to absorbing moisture from the atmosphere, which causes the plastic sheet to bubble when heated. Millions of tiny microscopic bubbles in clear plastics even though not noticeable with the naked eye, dulls the clarity of the plastic.

          Simple solution ................. buy new stock! But this is purely the testing stage, so I'm using up old stock.





          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


          • Very illuminating Turk mate [emoji1303]


            Sent from my iPad using Just T4s

            Comment


            • I guess I was just thinking of saving waste. The webbing is only a little bit of cosmetic issue... plus, if it is in the bottom corner, no-one will see it!

              BONGO FURY - 222bhp - 390lb/ft - 16.7064 1/4
              Are you quick enough for the T17.club?

              Comment


              • The corners get cut off Jim, they only get in the way of the OEM headlight retainer.

                Webbing is another way of your vacuum forming machine telling you that something isn't quite right! it's also a concern as it means the plastic is thinner in that area than the rest of the surrounding area. Finally got round to finishing the trimming of the headlight covers this morning, I was up till 02:00AM trying to finish those ready for today, didn't manage it though ............... eye-lids were having none of it!


                Corners cut off - you do get quite a clean cut with the Proxxon rotary tool, but you still have to finish off with a nice sharp knife >>

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                As far as I know I have just about got the cut-outs and the headlight cover mounting points in the correct places. But only a test fit to my van will tell >>

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                Headlight cover almost ready for a test fit. You'll notice that I've got two mounting holes ( securing holes ) on top of the covers, the plan is to have another two headlight securing positions under the covers, should make the covers a lot more rigid. As you've got a set of ProjektZwo' Jim, you'll know that they have two on top and only one underneath. But how that' going to work I don't know yet! As my previous plan went right out of the window, as I can't buy square rods of ABS! >>

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                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


                • Excellent stuff my good man.
                  BONGO FURY - 222bhp - 390lb/ft - 16.7064 1/4
                  Are you quick enough for the T17.club?

                  Comment


                  • Hi guys,


                    With my newly created headlight cover prototypes almost ready, I was planning a fitting to my van 'Lulu' .................. just had one more thing to do. Firstly, any of you remember this pic from the other forum a couple of years ago? It basically was a thought on how I would go about making the twin apertures for the quad headlights.

                    What at first looked rather easy, turned out to be quite complicated, having to measure a part with no flat straight sides or edges, positioning the twin apertures wasn't going to be easy >>

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                    So I had to come up with a fool-proof way of positioning those apertures, or at the very least, guide lines to help me measure-up more accurately ........ so this is what I came up with. >>

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                    Next up was to prepare my various containers for creating the holes ( apertures ), I found various diameters with varying degrees of conical angles, not sure what the correct term is but, it's the angle of the outer diameter and the inner diameter, as in the picture below >>

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                    First glance and everything seems to look OK, headlight assemblies fit perfectly ...................... >>

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                    And look the dogs danglies! ................ >>

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                    With the bottom cross section in place, the headlight mounting brackets just touch the the turned-up lip of the panel! There's no way I'm going to get the headlight covers on like that >>

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                    So the rest of the test fit was done without the cross section in place, as I still needed to see how the new prototype headlight covers fitted. I think the covers are OK, it's the mounting brackets that are the problem, they're touching on the inside of the covers at two different points. And it's causing the covers to twist making one side lower down than the other >>

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                    Not pretty I'm sure you'd agree. There wasn't much point in continuing with the twin aperture test, not until I resolve this issue >>

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                    So today, back to the drawing board!






                    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


                    • Come on Turk, keep on going, you're almost over the hill & homeward....

                      Not being funny but do you need these covers ie are the lamps not IPxx proof'? I like them without the covers , suits your van tbh.

                      Comment


                      • Oh man.... Lulu is one lucky lady....

                        Looking superb!!! the annoying thing is, that looks like "a few more days and it's done" now.... so peeps will get even MORE impatient.
                        In reality, I'm still guessing we are still a long way off.... from a combination of little tricky bits (the last 10% can take 90% of the time!) and also your super high standards.

                        Keep going chap!
                        BONGO FURY - 222bhp - 390lb/ft - 16.7064 1/4
                        Are you quick enough for the T17.club?

                        Comment


                        • Thanks chaps

                          yeah, your right Jim ............... one step closer to finishing the project, one issue detected and suddenly it's two steps back!

                          The mere fact that if you discover that a part doesn't quite fit correctly, a few millimetres out, it's not like working with wood where you would simply plane or sand it down, you have to go through the entire rigmarole of making some more moulds! 10 Kilos of Silicone rubber, 10 kilos of resin for the tooling plugs, and things begin to get expensive.

                          I'm not basing my project on costs, it's never been about money, the shear satisfaction of creating something that' useful is what keeps me going.

                          Time is the issue now, with so many people waiting on these, I do feel I have an obligation to them all.


                          After spending a considerable amount of time trying various things with the headlight mounting brackets, and the headlight covers in my workshop today, I've come to the conclusion that I will have to modify my tooling plugs, in order to vacuum form some more prototype headlight mounting brackets. I can't ( and won't ) be moving the units themselves, as I know that would be a futile exercise. Luckily I have a milling machine and resin mills very well I'm told. So instead of making some new tooling plugs I'll simply modify the ones I already have.




                          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 guys,


                            After a bit of fine tuning on the clear headlight covers, and confirming what I suspected, that the headlight mounting bracket was at fault, it's basically pushing the headlight cover to one side making the entire thing lopsided. Now things are beginning to look a little better >>

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                            Top of the headlight cover is dead inline with the edge of the underside of the bonnet, same gap all the way along, gap between the headlight cover and the indicator ........ the same >>

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                            Full frontal, the clear headlight cover is still touching that metal lip, so I will still need to modify my resin tooling plug. But I've got a milling machine so that shouldn't be too difficult >>

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                            Next step will be to workout the positioning of the twin apertures, but I need to mod the tooling plug first. It's only a few millimetres but that will make a difference to the overall look.



                            That's it guys for the time being ..................... thanks for looking







                            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


                            • Originally posted by TURK View Post
                              Hi guys,


                              After a bit of fine tuning on the clear headlight covers, and confirming what I suspected, that the headlight mounting bracket was at fault, it's basically pushing the headlight cover to one side making the entire thing lopsided. Now things are beginning to look a little better >>

                              [ATTACH=CONFIG]12212[/ATTACH]


                              Top of the headlight cover is dead inline with the edge of the underside of the bonnet, same gap all the way along, gap between the headlight cover and the indicator ........ the same >>

                              [ATTACH=CONFIG]12213[/ATTACH]


                              Full frontal, the clear headlight cover is still touching that metal lip, so I will still need to modify my resin tooling plug. But I've got a milling machine so that shouldn't be too difficult >>

                              [ATTACH=CONFIG]12214[/ATTACH]


                              Next step will be to workout the positioning of the twin apertures, but I need to mod the tooling plug first. It's only a few millimetres but that will make a difference to the overall look.



                              That's it guys for the time being ..................... thanks for looking







                              TURK
                              Amazing Job 🤙🏽[emoji1317]


                              T4ism is not a Dis-easeJust T4s

                              Comment


                              • Thanks mate Click image for larger version

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                                The resin tooling plugs will take more time unfortunately, I ordered the materials last week but with all these bank holidays the order' going to take a while. Not to worry, plenty to keep me busy in the workshop. Currently I'm having to make a sanding 'cone' as I couldn't find one with the correct angle on the Web. The obvious advantage of making your own tooling is you can custom make 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

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