Round two - FULL set of headlights from scratch

Topic: Round two - FULL set of headlights from scratch (Read 11069 times) previous topic - next topic

Round two - FULL set of headlights from scratch

Reply #45 – November 08, 2009, 05:34:48 PM

There are some projectors with solenoids for flash-to-pass. You could use those for low beams, your others for high. Some of the solenoids need an additional circuit, depending on the type of solenoid. (I've got both if you want some pics.)

My problem is I haven't yet figured out how to install them.

Round two - FULL set of headlights from scratch

Reply #46 – November 09, 2009, 08:09:14 PM

That's doesn't help when the lights are off and metal halide bulbs do not like being flickered on and off.

Round two - FULL set of headlights from scratch

Reply #47 – November 09, 2009, 09:09:45 PM

Sorry, my description fails.

The solenoids are fitted to HIDs that run as 'low beams', the solenoids flick a flapper that simulates a high beam flash-to-pass. In other words, you have low-beam HIDs with 'instant' flashing ability.

Round two - FULL set of headlights from scratch

Reply #48 – November 10, 2009, 08:36:03 PM

Bi-xenon - the projectors on my car right now do that. You still shouldn't use flash to pass when the bulbs are not lit. LED's do not care if you flicker them on and off.

Round two - FULL set of headlights from scratch

Reply #49 – November 17, 2009, 08:28:28 PM

If you're looking for something to flash when the headlights are turned off, couldn't you put some halogens somewhere for that purpose, especially if you're building your own? It shouldn't be too hard to wire something to switch between the halogens and HIDs based on whether the headlights are "on".

edit>>

OTOH, I've got nothing against LEDs. If you've got an idea on how to execute an install, go for it. You could even use a PWM for an infinitely (sort of) variable intensity. Label max as "11", just in case somebody oncoming fails to dim.

Round two - FULL set of headlights from scratch

Reply #50 – November 19, 2009, 01:08:45 PM

How much work would be involved to adapt this idea for Cougars? Would you consider? Just curious.

Round two - FULL set of headlights from scratch

Reply #51 – November 19, 2009, 03:55:51 PM

What about a hybrid solution--one bi-Xenon and one LED module per side, with the LED only for flash-to-pass?

Round two - FULL set of headlights from scratch

Reply #52 – November 19, 2009, 09:50:17 PM

Quote from: bike70ride;299401

How much work would be involved to adapt this idea for Cougars? Would you consider? Just curious.

When the time comes, I will have to see how easily I can pop one out for myself. I still believe the best way to do this is a special mold inside a vacuum forming box that will help the polycarbonate keep a seal so the vacuum will keep pulling the headlight all around the lens mold. The rear piece will likely just be formed from fiberglass as I don't trust injection mold plastics to hold up to the heat that headlights can put out. Again though, a decent mold would make this easy. The hard part is because we have no aftermarket clear lenses so retrofits onto our cars are a little more difficult.

I still haven't come up with a decent adjusting mechanism.

Round two - FULL set of headlights from scratch

Reply #53 – December 17, 2009, 03:30:18 AM

Did you ever complete a second set? Pictures?

Round two - FULL set of headlights from scratch

Reply #54 – December 19, 2009, 06:56:13 PM

No I haven't - I need another garage before I can get this done but there's a good chance it'll start next summer. I've got all the parts, I just need room to build my ideal vacuum forming chamber that will let me pull the polycarbonate from two angles instead of one like normal (pull down AND OVER). I have to do this right the next time, for a single piece front light set, or at the very least a two piece. Basically I need the corner piece to pull down to a point source to get the lens to wrap in along the front and side.

I expect I will waste a few hundred dollars in just s polycarb materials before I get a working chamber, then having to perfect a mold. It's not easy to get a piece vacuumed down AND over without storing a huge amount of vacuum - you need even heating, speed, and vacuum that can hold until the piece is wrapped around the mold. I've yet to figure out a way to remove the mold without destroying it if the piece will be the cornering lamp area.

Other car projects have also put this on hold but I'm pretty much out of things to do on it. Bug me again in a year and I may have some pictures of the current progress :p

Round two - FULL set of headlights from scratch

Reply #55 – December 30, 2009, 04:14:25 PM

LED's are sure getting up there in terms of efficiency. In the lab they are up to just about 190 lumens per watt now, absolutely dominating the 90 lumens per watt from HID. More light and less heat dissipation means easier retrofits (no need for a ballast).

Does anyone have any information on the actual laws on having more than 2 low beam lights? I've tried looking for cannot find much. I assume the middle lights on 05+ Mustangs are marketed as "auxiliary" or something?

Round two - FULL set of headlights from scratch

Reply #56 – December 30, 2009, 11:04:11 PM

Quote from: Seek;304448

LED's are sure getting up there in terms of efficiency. In the lab they are up to just about 190 lumens per watt now, absolutely dominating the 90 lumens per watt from HID. More light and less heat dissipation means easier retrofits (no need for a ballast).

Does anyone have any information on the actual laws on having more than 2 low beam lights? I've tried looking for cannot find much. I assume the middle lights on 05+ Mustangs are marketed as "auxiliary" or something?

The 05+ Mustangs are indeed fog lamps. The beam pattern shines in the area just ahead of the front end behind the low beams and spreads more to the sides.

Round two - FULL set of headlights from scratch

Reply #57 – January 31, 2010, 04:57:08 PM

I've got some parts coming that will be used for these headlights, including new bulbs that I will use in my currently headlights as my current ones are pretty aged by now and the light has diminished noticeably.

Does anyone have any ideas for an adjustment design that allows full up/down/left/right AND rotation adjustment? I'm thinking of using something like 4 threaded rods for the main adjustment and smaller bolts that can be loosened and tightened from the rear to allow rotation within a cut path. While crude, it is easier to build than trying to some up with a design that can rotate the projectors using a threaded rod which WOULD allow for simpler adjustment though. Either way, with our header panels, the headlights would have to be removed from the car to be adjusted in any case.