Lupo Headlights

[ProjectChimaera]

I've just removed my Mk11 Chimaera headlamps and reflectors. What an awful design! I need two reflectors and one lense.
The Lupo headlamps look like a better option as much more modern design and sealed.
I can't find a step by step guide, could anyone point me in the right direction?
How much cutting is involved and how was the modification process?
Any advice would be most welcome in helping me decide which way to go.

I have also considered the Mk111 mod and using Mk 1 golf lamps but I actually think I prefer the original headlamp look?

[ProjectChimaera]

Engineer1949 said:

your right about the bezel restricting the beam but if correctly fitted and the bezel then painstakingly reworked to fit ezactly around the periffery of the lens as i did with nicks which involves reshaping the bezel totally i used a thin copper tube soldered together in a circle then shaped around the lens edge and finally using epoxy and fine tape refashioned the bezel but result is brilliant in more ways than one

tvr_9_march 7 by Brundall Motorsport, on Flickr

john

Edited by Engineer1949 on Saturday 20th August 08:02

Thanks John, I've had a look at your blog and it's a big help.
How easy was it to actually mount the lamp units? Fashion some brackets and sikaflex to body?
It would be easy to just spend the money and go back to stock but I hate the design and probably the likely beam quality. I just want to be sure it's worth the effort? Looking at Nicks car and others I really like the fresher original look when done.

[ProjectChimaera]

tofts said:

I don't lnow weather it is possible on the Chim, but on the cerb I actually used the cowl as the mount for the lights, this makes them removable if one breaks or becomes mikly with age!

Edited by tofts on Saturday 20th August 11:25

j

Thanks, that's really interesting, presume you moulded those fixings around the Lupo lamp shape. What did you use to create the shape? Do the cowls still mout the same way with a couple of lower fixings and sikaflex at the top?

Car looks great btw.

[ProjectChimaera]

DangerousDerek said:

What are these bezels and cowls you all speak of?

,
That looks cool too! That amount of bodywork is way above my talents I'm afraid. If it doesn't involve a spanner I get nervous!

[ProjectChimaera]

tofts said:

Pretty much, I carved most of the "inner" cowl away, leaving parts at the top and bottom to accommodate the fixings. The fixture i created by covering the light in cling film then placed glass over the approx area I needed. I then went on to make further molds of these so I could do the job in the future on other cars to make it easier. Thankfully, there is enough meat in the inner cowl to support the mods, but im not certain it could be done this way on a chim. I do have a potential conversion for a customer on the horizon, so if it is possible this way, I will put something up about it. I never liked the idea of having the light fixed permanently!

Jody

Thanks Jody, I've ordered one Lupo lamp so that I can offer it up. I'll post accordingly when I've had a look. The creation of the mould technique is pretty cool!
Where are you in Essex, I suspect I'm not that far away in Suffolk?

[ProjectChimaera]

A really frustrating day trying to get the Lupo headlamps in.
John kindly advised that he reshaped the bezels to get a decent fit, has anyone ever fitted these without modifying the bezel?

It doesn't look like that I can get the lamp unit in anywhere near upright or square without relieving the lower edge of the bezel?

No matter how I try I either get an unsightly gap at the top or bottom between the lamp an bezel.

[ProjectChimaera]

phazed said:

No way will you fit the unit without trimming the bezel.

Don't worry about it, trimming the bezel is the easiest part!

Thanks Phazed, I was looking for a little reassurance that I was on the right track!

I've got the existing area all cut out and I can get the lamp pretty much where I want it but not with the bezel anywhere close.

At least the other side should be a little easier as I can cut with confidence.

Once again thanks.

[ProjectChimaera]

Not a job for the feint hearted this one is it?
That's two days of my life I'm never getting back and I haven't finished yet.
At least the lamps are in and the brackets made are supporting them to some degree in the correct position.
A few more brackets to make and fix and then I can look to reshape the bezels which scares me a bit.
I hope it's all worth it in the end, after you've started cutting the old lamps away you do begin to wonder!

[ProjectChimaera]

portzi said:

looks like you have almost completed the hardest part, enlarging the original hole to receive the Lupo unit, and manufacturing a support bracket to hold it securely in place. As mentioned the bezel is simple to do, and once you have done one side you have a mirrored pattern for the other-side, it is surprising how much is filed off to make them fit.

If you have trouble getting them to fit perfectly flush to the body at the top of the light, I filed a small amount off the top of the light see picture as mine had a slight radius at the top of the light which was preventing them to fit perfectly flush, with no body gaps.

My Lupos were also bolted to the body using a Ali bracket



Thanks for the info, much appreciated.
How did you do the bezels? I thought I might mark the outline of the new lamps and then remove them, offer up the bezels and try and get some measurements to cut to?

It looks like there will be plenty to cut off the bottom edge! Slightly scary but so is the whole task.

Do the bolts in your picture attach to some of the brackets fabricated to support the headlight base?

[ProjectChimaera]

portzi said:

Q1. Thanks for the info, much appreciated.
How did you do the bezels? I thought I might mark the outline of the new lamps and then remove them, offer up the bezels and try and get some measurements to cut to?

Yes your correct,I cut a template using cardboard of the the light circumference and offered it up to the bezel, then as you said marked out the bezel to give a guide to work too.

Q2. Do the bolts in your picture attach to some of the brackets fabricated to support the headlight base?

Yes they are part of the support bracket for the light.

Cheers

[ProjectChimaera]

SILICONEKID345HP said:

They ain't much fun to fit, I think a little sikaflex around the edge might just provide some additional support.

[ProjectChimaera]

Bezels cut ( I made a much better job of the second one)brackets finally bolted in. A little sikaflex will be needed at the front around the headlamp for final fix but will wait to see what the beam pattern looks like first.
A great tip from Portzi regarding filing the headlamp at the top, don't think you could bet the bezel to fit nicely without doing it.

Not sure if my bracket system is the best way of doing the job but they are sturdily fixed and time will tell.

If anyone is looking at this for reference in the future then the following may help.

1, It's unlikely that you will complete this quickly, it needs some thought and lots of tea while you stare at what you are going to do next.
2, Dont worry about the bezels, your first job is to get the new headlamps in the hole looking straight and level.
3, You will have to cut a lot out to get the lamps in position.
4, I cut two of the existing headlamp mounts off.
5. Make a template in cardboard of the enlarged access hole for the inner wheel arch, test that the new headlamp will go through it before cutting it out. Again this will be quite a large hole.
6,Consider how you can temporarily support the new lamp in place whilst making brackets etc. I found the alloy cross bar stopped it falling out whilst fabricating.
7, Clamp up the brackets as you go, looking and lining up the front is messy.
8, Be careful how far through you bring the lamps, the top edge is a difficult fit behind the bezel.Re Portzi's filing tip.
9, I used the remaining headlamp mount for for and aft support with a threaded bar(see photo) this may be a bit of overkill but is easy and worked for me.
10. I glued the support bracket to the inner wing.
11, I decided not to use the headlamp multi plug for the wiring. I notched out the bulb cover to let the existing wiring through. The headlamp connection is the same and a couple of terminals will take care of the sidelight.

Not an easy job, but looks nice when done and a sense of achievement when completed.

On to the next job of which there are many!

Thanks to everyone who offered excellent advice along the way.

[ProjectChimaera]

portzi said:

fantastic work Adrian,lights looking great. Is that your finished position for the Lupos? As it maybe a trick of the light of the camera angle, but maybe the lupo could sit afew mm's lower? Keep the pictures coming please.

Edited by portzi on Friday 26th August 13:37

Thanks, trick of the light I think. It looks like there is a gap at the bottom of the light/bezel but there isn't it's pretty tight.
I'll try and post a better photo