LED headlight conversion NOT HID. Impressed so far.

LED headlight conversion NOT HID. Impressed so far.

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Discussion

Sohlman

Original Poster:

590 posts

253 months

Sunday 29th March 2015
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I have only been using this forum for 5 months and it staggers me how helpful you all are.

I am down at a Monkfish on Wednesday for a service 8:30 am ouch. Depending on where you are I could pick up on my way back to Woking. I actually really like the red.

KMud

2,924 posts

155 months

Sunday 29th March 2015
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I'm in Bristol, probably a postal job.

Had 2 power cuts today! Lots of wasted plastic. Will check if the revised design is any cop smile

Sohlman

Original Poster:

590 posts

253 months

Monday 30th March 2015
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Bristol is a bit far for me on Wednesday. Do you want to PM me and I will pass on my details. Plus I would be keen to make a contribution to the plastic/postal fund 3d printer fund.

Moving back to the lights I now have blood on my hands.

I removed the drivers side cover to check on how hot the insides where on the Philips bendy bits after an hours drive. The amount of space between the cover and battery is tight thus the blood on my hands. I am happy to find that Luke warm is all they where which is good.

I have also taken a couple of photos on my road this evening in the dark this time.

Dipped beam



Full beam


KMud

2,924 posts

155 months

Monday 30th March 2015
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I had a couple more power cuts (high winds, Mr. tree met Mr. transformer I'm told), but I've got a pair of the revised design (wider, and +10mm depth now) at ~80%. Pics to follow. You may opt for the ones closer to the original design. Wednesday might have been pushing it at this rate anyway!

Logically, the easy answer is spacers. Those I could mass-produce at a reasonable cost...I just might need to invest in some rubber filament to print my own seals, or find something appropriate to buy-in.

Sohlman

Original Poster:

590 posts

253 months

Monday 30th March 2015
quotequote all
I am truly amazed by this 3d printing it's so interesting. Been visiting YouTube.

Re the seals I am sure you could buy from a plumbers merchant if the diameter is known. They may be available from Vauxhall, GM. I can't believe something like that is expensive.

Thanks so much for your time and effort on this little project. Whatever happens I owe you a beer or two.

When HID's came out I bought one of the first kits which cost me over £300 and fitted to my 635csi. I wrote it all up and caused a bit of a revolution. Many owners have done the same. It took me 8 hours to fit and I lost a lot of blood, but the results where great. 12 years later it failed and was replaced last year. The ballasts halved in size and price was a third. However this LED kit is far smaller again.


Wyld Stallyn

2,056 posts

127 months

Monday 30th March 2015
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KMud said:
Logically, the easy answer is spacers. Those I could mass-produce at a reasonable cost...I just might need to invest in some rubber filament to print my own seals, or find something appropriate to buy-in.
Nice idea / Plan thumbup O-Ringc would be my suggested solution to that one: cheap, flexible and proven...

smgee

81 posts

141 months

Tuesday 31st March 2015
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KMud

2,924 posts

155 months

Tuesday 31st March 2015
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Trialled the 'fattie' design (left) - I don't like it, I would only go there if the bulbs demanded it (hard to grip, ugly). The one on the right is the current revision, basically like OE, but 10mm longer, a bit bigger inside, and with chamfers (which minimise the need for printing support)...I'm still fiddling slightly with the details, but I think that's basically it. I'm beginning to run low on red, the ones I send out may be black (unless you have a preference). There are funny options like a thermal-reactive plastic that changes colour above 35'C scratchchin

Sohlman

Original Poster:

590 posts

253 months

Wednesday 1st April 2015
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Been at monkfish all day today peering at the back of headlights.

The late facelift 6.0 vxr cars require the angled covers on both dipped beam due to battery on drivers and the coolant filer on the passenger side. Main beam is not an issue for space. I have seen cars with both 65ah and 72ah batteries. With a 65 there is some space, but the 72ah is fag paper sized gaps.

KMud

2,924 posts

155 months

Wednesday 1st April 2015
quotequote all
Sohlman said:
Been at monkfish all day today peering at the back of headlights.

The late facelift 6.0 vxr cars require the angled covers on both dipped beam due to battery on drivers and the coolant filer on the passenger side. Main beam is not an issue for space. I have seen cars with both 65ah and 72ah batteries. With a 65 there is some space, but the 72ah is fag paper sized gaps.
I'd need to see it - not studied the later coolant system but would have assumed the battery tray was the same. IIRC the battery could be moved a little in the tray before locking it down, but I've since hammered my tray flat so I could fit a bigger battery (and it's about to leave the engine bay entirely...).

Supposed 'final' design caps #4 and #5 should finish within the next hour or so, if you're happy with red then email me your details and I'll try to find a box and a PO smile

IXLR8

2,025 posts

148 months

Thursday 2nd April 2015
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KMud said:

bow

They look wicked....Yeah the RHS look better cool

Your a true gent KMud clap

bow


Sohlman

Original Poster:

590 posts

253 months

Sunday 5th April 2015
quotequote all
Thanks so much to kmud I now have received the covers. They look ace.

I have fitted one on the main beam unit which fits like a glove re using the original seal.

The back of the LED bulb without cover



With the new sexy cover fitted



The rest require a bit more time and some tool action

KMud

2,924 posts

155 months

Thursday 9th April 2015
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Did my mains in John Major grey. The driver's side was tight, but ultimately fits (and hopefully never to be opened again!). Might take a couple of mm off the outer webbing if were doing it again.



Again, tight stuffing, I'm sure there's a knack but bit of a bugger stuffing it all in. Hopefully nothing in there will get cooked!


(upper is main, lower is parking light)

Gratuitous insta-flash video

Sohlman

Original Poster:

590 posts

253 months

Thursday 9th April 2015
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Kmud I have now made a donation to your plastic refresh fund. If you can let me know its arrived safe.

It's a tight fit for the cables, but clearance was fairly good for the bulb itself although closer on the drivers side.

The heat should be ok as its only 20w and with the fan it pushes it forwards towards the light. I ran the mains for 10 mins and while the fans came on, they where cool to the touch. I have never had the mains on for 10 mins, but I can't believe they will get any hotter than this. Time will tell

Personally I am more worried about the strap system on my dips, but again after 1 hour on they were Luke warm.


KMud

2,924 posts

155 months

Thursday 9th April 2015
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Cheers, got it - I appreciate you effectively bank-rolling the development...find any faults and I'll do you a fresh set with tweaks smile

chrisgixer

153 posts

159 months

Thursday 9th April 2015
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Wow that's a great idea.


Could the 3D printer blue used to make Polly bushes?

KMud

2,924 posts

155 months

Thursday 9th April 2015
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You first! Probably not up to it...can do ABS and rubber (ninjaflex) on my machine, and some machines can do nylon...but I think bushes would want forming in a single injection.

chrisgixer

153 posts

159 months

Thursday 9th April 2015
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Yes sorry, was between tasks.

Apologies for off topic questions, but rear subframe (by the dif, not the donuts) mounts on the omega are no longer available from vx. And nobody makes poly for those. Tooling would be costly. It's an inanimate lump with minimal motion on it, not like wishbone bushes or something with friction motion directly on the part.

We are looking at removing the rubber from the existing bracket, although that's the failure mode anyway, and re using it with an insert. Early attempts involve a mould and poly mix. It's not been too successful .

But an accurately made insert fitted in the u shaped bracket would work. Then an insert within that reused for the subframe bolt, then just bolt it up.

Even vx dealers are searching eBay for used ones to service their customer cars.

KMud

2,924 posts

155 months

Friday 10th April 2015
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Would it be a good idea to 3D print the mould, and use 2-pack polyurethane?

Sohlman

Original Poster:

590 posts

253 months

Friday 14th August 2015
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By way of an update I have now been running these lights for 4-5 months now.

Performance is at the same level as when first fitted so no drop off in light output which is good.

Have now fitted the covers on the other side when I installed my cold air intake last week and no signs of any damage or stress on the plastic from the straps so it runs cool enough to not pose problems which again is good news.

Though this might be beneficial for those thinking about this option.