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Old 28-01-13, 21:24
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TURK TURK is offline
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T4 Post Icon Quad headlight design project ..... Update

Hi all,

I've been working on a quad headlight design for a couple of years now, weekends mostly. Had quite a lot of issues as you may imagine. Nothing I can't deal with though.

The design has changed quite considerably in the last year. I can safely say that I'm almost there. But I need some assistance.

I'm currently after set of headlight brackets. second hand if poss. ( obviously trying to keep the costs down ).

Here's what I'm after ..... what looks like number 2 in the diagram >>



To better explain, here's a picture of an old one I took a couple of years ago ...... already modded ! >>





I'm after an 'unmolested' set, as I realise now I cut away too much
we do have a breakers in Jersey, but they're next to useless ! they'd probably say ...... what's a T4 ?



Quick rundown how things are going, if anyones interested .....

On a previous thread I posted the 'test rig' with all the wiring and switching complete. The 90mm headlamp units are by Hella.
The high beam is of reflector type and the low beam is a projector type ( switchable LHD/RHD ). In high beam all four units are on.
These things are so bright you wouldn't believe ! you can actually feel the heat off them ! >>







I had to design the mounting brackets for the units from scratch, it took literally day's just measuring. I then sent my design to be lazer cut. When I received the templates back ( 2 months later ), I was surprised to see that they had used 2mm stainless steel, instead of the 1.5mm I had requested !
Oh well, they're here now, I may as well try to fit them. I did email them, they apologised profusely, and told me they would send replacements FOC in 1.5mm.

In the meantime, I had a fitting to do. >>




When I 'married' them up, they looked OK, great .... all I got to do now is to shape the mounting tabs to fit the bulkhead.
Not so easy with 2mm stainless steel ! I wanted to use stainless steel for two reason, one; no corrosion, and two; no flexing.
There's nothing worse than poor headlights that judder when your engine is on idle. >>




As I don't have a workshop ( I don't even own a vice ! ) bending the mounting tabs was just impossible for me.
Here's the resulting 'farce' >>




So I packed up for the day, disappointed to say the least

I realised the tabs were an issue, so I asked the steel fabricator to cut all the tabs off, before sending me the 1.5mm ones, as I knew I would struggle with those as well. A few days later they arrived. Now I was in the position to mount the headlight units into the mounting frames ( as this step could not be done with the 2mm templates ..... too thick ! ).

One of the major issues had been resolved many months ago ..... how to put x2 90mm units side-by-side in the aperture provided in the bulkhead. Here's what you've got to play with >>




And here's a shot of the rear of the 90mm Hella units. And these units are quite compact ! >>




Hight beam and low beam mounted in the mounting frames, are fully adjustable >>




As bending and twisting the steel tabs is such an issue, I found a way around it. Why not mount my 'template' into the original VW mounting frames !? ...... The original idea I had over a year ago
Thing is, back then, I was toying with the idea of installing two 120mm units side-by-side. A designed I dropped very quickly, as it's not possible.



This is where the project has stalled >>




In the picture above you can just see the VW mounting bracket, fitted to the bulkhead.
Now I'm sure you can appreciate the need for me to get my hands on some of these brackets. Cheap as possible, as I'm going to remodel them.



Sorry to have taken so much of your time, but it's for a good cause .... I think





TURK

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Quad Headlight Project & in the Classifieds Section
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  #2  
Old 28-01-13, 21:31
Mike-S Mike-S is offline
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T4 Post Icon Re: Quad headlight design project grinds to a halt ..... again.

Good work Is it the threaded adjusters that you need? I'm near positive I have some in my spares box if so, could even be brand new
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  #3  
Old 28-01-13, 21:50
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TURK TURK is offline
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T4 Post Icon Re: Quad headlight design project grinds to a halt ..... again.

Hi Mike-S,

Thanks for the quick response

No, not the adjusters ..... the actual mounting frame.
The black plastic thing in picture #2


Thanks mate.



TURK

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  #4  
Old 28-01-13, 22:30
Mike-S Mike-S is offline
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T4 Post Icon Re: Quad headlight design project grinds to a halt ..... again.

Ah sorry, viewing this on the iPad and it didn't load all of your pics first time around for some reason...I don't have any spare frames
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  #5  
Old 29-01-13, 07:21
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TURK TURK is offline
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T4 Post Icon Re: Quad headlight design project grinds to a halt ..... again.

No worries Mike.

Breakers in the UK that specialise in T4's is probably what I'm looking for.
No doubt they'll try and sell me the entire headlamp unit.




TURK

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  #6  
Old 29-01-13, 09:59
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Bonzey Bonzey is offline
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T4 Post Icon Re: Quad headlight design project grinds to a halt ..... again.

Vary interesting, what have you planned for the outside trim ?
I might be able to help with the parts you need. I will have a look next weekend and get back to you.

Bonzey
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  #7  
Old 29-01-13, 10:50
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TURK TURK is offline
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T4 Post Icon Re: Quad headlight design project grinds to a halt ..... again.

Hi Bonzey,

Will be making shrouds from fibreglass.
I need to find out the depth of the shroud first ( ie, how far in the Hella units will be ).

I've already got some shrouds made up, for testing purposes. Helps me to align the headlamp units correctly.
Otherwise you're in danger of setting them up 'pigeon toed'.


I've spent a couple of days searching the net for the brackets. so far I've only found one offside at a breakers, via ebay.
I may just order a brand new set of headlights.




TURK

Lulu Build Thread
Quad Headlight Project & in the Classifieds Section
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  #8  
Old 29-01-13, 19:16
Puddles McSqeakybeak Puddles McSqeakybeak is offline
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Default Re: Quad headlight design project grinds to a halt ..... again.

I've got an entire headlight you can have, can't remember what side though.
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  #9  
Old 29-01-13, 19:52
camperwagen camperwagen is offline
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Default Re: Quad headlight design project grinds to a halt ..... again.

iv got some at work ill get them tomorow for you pm me your adress
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  #10  
Old 29-01-13, 19:54
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Russ Dylan Russ Dylan is offline
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Default Re: Quad headlight design project grinds to a halt ..... again.

You are a legend in your own lunchtime, when you complete this task, may i place myself in the Q for a set, they are going to be so cool
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phares t4, quad headlights, t4 transporter, vw t4 quad scheinwerfer, vw t4 twin headlights

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