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

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  • Thanks Greeny

    When you're designing something Greeny, there's so much research involved that a lot of people wouldn't even know where to begin. When you look at the early days of the project, on the other site as most of the project isn't covered here, you'll see that I struggled with the materials for quite a while. But now I'm pretty sure that I've found my materials that I'll continue using for mould making, special resins and silicones that is. As the results I'm now getting are fantastic.

    But then you also have to learn how to use them, the amount of shrinkage I ended up with on my silicon moulds is the cause for me having to modify my existing resin tooling plugs. Baring in mind, I'm still at the prototyping stage, things can only get batter I think !




    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


    • Shame mate, that said I don't think it's gonna hurt the sales too much not having it, oem are crap lol 👍😁

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

      Comment


      • Originally posted by Thebigredone View Post
        Shame mate, that said I don't think it's gonna hurt the sales too much not having it, oem are crap lol 
        'Shame' ? no, not really ..................... I have a manual headlight beam adjuster in my MultiVan, I set it two years ago when I bought the van ..............
        I've never had to re-adjust it since !

        The T4's suspension is so stiff in comparison to a regular car, as in a four door saloon when you carry passengers in the rear, then you would notice the difference. The rear end would go down because of the extra weight in the back, causing your headlights to shine higher up, then an adjustment would come in handy. But in a heavy vehicle like a van, not really necessary.

        I'de much prefer to concentrate on the lights performance and quality actually.




        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 mate, onwards and upwards 👍😁

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

          Comment


          • Originally posted by tommo1366
            I’ve stayed on it to follow the Vee Dub family and a few others that post meets and festivals etc. I’m on here all the bloody time now! Keep spreading the love!


            Sent from my iPhone using Just T4s
            You going to the Haynes museum next month ?


            Sent from my iPhone using Just T4s

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            • Yes we certainly intend to, although Mrs is out on the 17th so may just be me and the boy if she’s hungover.. you?


              Sent from my iPhone using Just T4s
              Slowly slowly catchy monkey!

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              • Hopefully yeah we will , got my lads that weekend and youngest love his motors , 🤙


                Sent from my iPhone using Just T4s

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                • Be good to put some faces to names!


                  Sent from my iPhone using Just T4s
                  Slowly slowly catchy monkey!

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                  • Hi Guys,


                    Just a quick update to let you know where we're at.


                    As I'm currently at the headlight covers design stage, and the rest of the assembly is pretty much a 'universal' thing ......... headlight mounting bracket was an absolute mare to get right, it has to be able to support all the different variations of the Hella modular units. All of which are different ! So I had to make three different prototypes.

                    In the picture below I have to the left the 'Performance Series' - top middle the 'Classic Series' and to the right the 'Premium Series' >>




                    I'll go into greater detail at a later, as right now I'm rather busy wiring stuff !




                    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


                    • Looking good mate

                      Sent from my SM-G930F using Just T4s

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                      • They are looking brilliant Turk

                        Sent from my SM-G930F using Just T4s

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                        • Originally posted by TURK View Post
                          Hi Guys,


                          Just a quick update to let you know where we're at.


                          As I'm currently at the headlight covers design stage, and the rest of the assembly is pretty much a 'universal' thing ......... headlight mounting bracket was an absolute mare to get right, it has to be able to support all the different variations of the Hella modular units. All of which are different ! So I had to make three different prototypes.

                          In the picture below I have to the left the 'Performance Series' - top middle the 'Classic Series' and to the right the 'Premium Series' >>




                          I'll go into greater detail at a later, as right now I'm rather busy wiring stuff !




                          TURK
                          What’s bottom middle? Or is that a dumb question and half and half performance and premium?!


                          Sent from my iPhone using Just T4s

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                          • Originally posted by Sirfbum View Post
                            What’s bottom middle? Or is that a dumb question and half and half performance and premium?!

                            Yeah, as you say, half and half. You can see that the two on the right have a much larger lens, those are the 'Premium Series' as they're Bi-Halogen units.

                            Glad you like them so far chaps but you won't actually be seeing that part, as that's the underlying structure.

                            Here's a bit more info, as individual quad headlight systems and some techy stuff. For me a good set of headlights must look good, look as though it's designed to fit that particular vehicle, but most importantly they must perform well. The ISOLux charts give us an idea of the coverage of each Hella unit as tested by Hella themselves.








                            The 'Classic Series' that have the H7 type bulbs >





                            Low Beams ISOLux Chart - up to 125 meters>>





                            High Beam ISOLux Chart - up to 260 meters >>







                            The 'Performance Series' that have the H1 type bulbs>>





                            Low Beams ISOLux Chart - up to 150 meters >>





                            High Beam ISOLux Chart - up to 280 meters >>







                            The 'Premium Series' that have the H7 type bulbs >>





                            Low Beams ISOLux Chart - up to 150 meters >>





                            Tried as much as I could but I couldn't find the ISOLux Chart for the high beams for the Bi-Halogens I'm afraid. So if we assume the difference is about 90% greater between the low beams and the high beams going by the other ISOLux charts, the high beams on the Bi-Halogens will be about 280 meters, maybe a tad more so lets say 300 meters.


                            Just because the units themselves are more expensive than the 'Performance Series', it doesn't actually mean they are going to be much brighter and give you more visibility. Personally, I think it's more of a convenience thing having a dual headlight unit. Also, lets not forget that the Bi-Halogens are a H7 unit and not the more powerful H1 bulb type.


                            I'm sure you all know how to read an ISOLux Chart, but for the uninitiated the colours basically mean the amount of light dispersed. Light decreases with distance, so the brighter areas ( yellow ) is where the light is at it's most intense, as it decreases it goes from light green to dark blue. They never actually indicate how the tests were carried out, particularly what type of bulb they used ....... but I'm pretty sure that if a power bulb such as the Philips ExtremeVision 130+ were used, we could possibly squeeze out a few more meters !




                            Back the 'Premium Series' quad headlight system ......... On closer inspection and as good as they look, there are some issues With the units fully adjusted inward, they still stand out too proud, I would really need for them to sit further inward. As there's another part to fit in there yet. But I'm pretty sure I can do something about that >>





                            There's quite a lot going on round the back as you can see. The two pig tails you see there with the twin SuperSeal connectors, are for the solenoids that operate the low beam/high beam shields >>







                            That's it for now guys, really can't wait for the next bit, should be quite interesting












                            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


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

                              Did you figure out a tool for cutting the holes eventually?

                              And do you have charts for standard lights - for comparison?


                              Sent from my iPhone using Just T4s

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                              • I'm hoping to use the CNC for cutting the holes out of the vacuum formed parts. Also, I intend in using the CNC for the development of the long nose version of the quad headlights.

                                No ISOLux charts for the VW OEM headlights I'm afraid mate, they have been in circulation for almost 30 years ! The comparison tests will have to be done in real time. So forum members will actually see the difference between the units, and other aftermarket headlights. Should be quite interesting



                                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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