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> HID headlights in the pods for Neo914, Pop-up headlights are not in the plans..
neo914-6
post Jan 10 2006, 09:34 AM
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I'm getting a quote on prototypes that are flat on the back to reduce costs. Concavity will cost more. This means I need to recess them to clear the flat surface.

That would be nice if you can find a lense the same shape and size.

I'm considering injection molding crystal clear lenses the same shape as original for production...
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rick 918-S
post Jan 10 2006, 10:23 AM
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I didn't read every post but did anyone suggest making a vacum mold in the shape of the factory lens and pulling in some lexan?

I've done it for a motorcycle faring lens cover. It's easy. (IMG:http://www.914world.com/bbs2/html/emoticons/confused24.gif) Just besure the lens is deep enough to trim off the sandwich flange.

check the Alien build thread link at the bottom of my post for a simple vacum mold I made for a fan shroud. You may need a vacum pump but I just used my shop vac.
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neo914-6
post Jan 10 2006, 01:56 PM
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QUOTE (rick 918-S @ Jan 10 2006, 08:23 AM)
I didn't read every post but did anyone suggest making a vacum mold in the shape of the factory lens and pulling in some lexan?

I've done it for a motorcycle faring lens cover. It's easy. (IMG:http://www.914world.com/bbs2/html/emoticons/confused24.gif) Just besure the lens is deep enough to trim off the sandwich flange.

check the Alien build thread link at the bottom of my post for a simple vacum mold I made for a fan shroud. You may need a vacum pump but I just used my shop vac.

I vacuum formed lexan in school but how do you replicate the seal channel? I'm talking to a plastic fabrication company who could vac mold sets of them from a sheet, it still the tooling that takes time/expense...
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plymouth37
post Jan 10 2006, 03:32 PM
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nice work! I have been kicking this idea around for a long time, it's nice to see you actually pull it off! do you have the aplication and/or part numbers for those headlights, price? where did you get the turn signals? brand?
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rick 918-S
post Jan 10 2006, 05:03 PM
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QUOTE (neo914-6 @ Jan 10 2006, 11:56 AM)
QUOTE (rick 918-S @ Jan 10 2006, 08:23 AM)
I didn't read every post but did anyone suggest making a vacum mold in the shape of the factory lens and pulling in some lexan?

I've done it for a motorcycle faring lens cover. It's easy.  :confused: Just besure the lens is deep enough to trim off the sandwich flange.

check the Alien build thread link at the bottom of my post for a simple vacum mold I made for a fan shroud. You may need a vacum pump but I just used my shop vac.

I vacuum formed lexan in school but how do you replicate the seal channel? I'm talking to a plastic fabrication company who could vac mold sets of them from a sheet, it still the tooling that takes time/expense...

I wouldn't worry about replicating the sealing channel. Just be sure the outside diamension is the correct width to match the housing.

Another option would be to make the sealing flange out of flat stock, polish all the edges and glue the polished clear plastic sealing flange, to the polished vacum formed light cover. Then re-polish. the bond line would become near invisable.

Easy peasy... (IMG:http://www.914world.com/bbs2/html/emoticons/wavey.gif)
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neo914-6
post Jan 10 2006, 05:19 PM
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QUOTE (rick 918-S @ Jan 10 2006, 03:03 PM)
I wouldn't worry about replicating the sealing channel. Just be sure the outside diamension is the correct width to match the housing.

Another option would be to make the sealing flange out of flat stock, polish all the edges and glue the polished clear plastic sealing flange, to the polished vacum formed light cover. Then re-polish. the bond line would become near invisable.

Easy peasy... (IMG:http://www.914world.com/bbs2/html/emoticons/wavey.gif)

Super, I'll take two sets! (IMG:http://www.914world.com/bbs2/html/emoticons/biggrin.gif)
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rick 918-S
post Jan 10 2006, 05:45 PM
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QUOTE (neo914-6 @ Jan 10 2006, 03:19 PM)
QUOTE (rick 918-S @ Jan 10 2006, 03:03 PM)
I wouldn't worry about replicating the sealing channel. Just be sure the outside diamension is the correct width to match the housing.

Another option would be to make the sealing flange out of flat stock, polish all the edges and glue the polished clear plastic sealing flange,   to the polished vacum formed light cover. Then re-polish. the bond line would become near invisable.

Easy peasy... (IMG:http://www.914world.com/bbs2/html/emoticons/wavey.gif)

Super, I'll take two sets! (IMG:http://www.914world.com/bbs2/html/emoticons/biggrin.gif)

I like your light idea. Sorry no time to build vacum molds today. Too much worky... (IMG:http://www.914world.com/bbs2/html/emoticons/sad.gif)
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neo914-6
post Jan 11 2006, 01:21 PM
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QUOTE (plymouth37 @ Jan 10 2006, 01:32 PM)
nice work! I have been kicking this idea around for a long time, it's nice to see you actually pull it off! do you have the aplication and/or part numbers for those headlights, price? where did you get the turn signals? brand?

Dana,

Thanks, info is in this thread...tell Scott (IMG:http://www.914world.com/bbs2/html/emoticons/wavey.gif)
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cbenitah
post Mar 31 2006, 11:54 AM
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QUOTE (neo914-6 @ Dec 30 2005, 12:51 AM)
Finally chose an LED signal light which will help finalize the package. They are small and used in motorcycles...

I've been conversing with a plastic molder and got a quote from Tony's injection molder connection for the lense. If I went to production how many people will want to use them for headlights or just clear signal lights? It's a big tooling investment so I'll have to (IMG:http://www.914world.com/bbs2/html/emoticons/idea.gif) this awhile....

I am in! When can I get a set? (IMG:http://www.914world.com/bbs2/html/emoticons/clap56.gif)

Will the projector light do High beam as well or do you have to add another one underneath the one you got?
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TonyAKAVW
post Mar 31 2006, 12:50 PM
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Things are in progress. I will try to get an update today or this weekend on the progress.

QUOTE
Finally chose an LED signal light which will help finalize the package. They are small and used in motorcycles...

I've been conversing with a plastic molder and got a quote from Tony's injection molder connection for the lense. If I went to production how many people will want to use them for headlights or just clear signal lights? It's a big tooling investment so I'll have to  this awhile....


-Tony
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neo914-6
post Apr 2 2006, 01:19 AM
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Great news Tony! (IMG:http://www.914world.com/bbs2/html/emoticons/wink.gif)

Formed some aluminum sheet in the bucket, I'm no John Kelly but I think the results were nice... (IMG:http://www.914world.com/bbs2/html/emoticons/cool.gif)


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Andyrew
post Apr 2 2006, 04:51 AM
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Mmm Yup..

Those are nice!

Now.. didnt you say that would "possibly" melt fiberglass?

I really think thats a killer setup...
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neo914-6
post Apr 2 2006, 11:53 AM
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QUOTE (Andyrew @ Apr 2 2006, 02:51 AM)
Mmm Yup..

Those are nice!

Now.. didnt you say that would "possibly" melt fiberglass?

I really think thats a killer setup...

HID heat will melt the lenses but they will be mass produced so I will have spares (IMG:http://www.914world.com/bbs2/html/emoticons/wink.gif) We'll see, headlight cooling system will be next. (IMG:http://www.914world.com/bbs2/html/emoticons/laugh.gif)

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Dougs914
post Apr 2 2006, 07:57 PM
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(IMG:http://www.914world.com/bbs2/html/emoticons/pray.gif) Put me down for a set.
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Andyrew
post Apr 3 2006, 02:18 AM
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QUOTE (neo914-6 @ Apr 2 2006, 10:53 AM)
QUOTE (Andyrew @ Apr 2 2006, 02:51 AM)
Mmm Yup..

Those are nice!

Now.. didnt you say that would "possibly" melt fiberglass?

I really think thats a killer setup...

HID heat will melt the lenses but they will be mass produced so I will have spares (IMG:http://www.914world.com/bbs2/html/emoticons/wink.gif) We'll see, headlight cooling system will be next. (IMG:http://www.914world.com/bbs2/html/emoticons/laugh.gif)

If you do make another set.. or a bad set.. or something... let me know... I'll take one of your prototypes and use it on my car... I think it would look sick! (im leaning towards black for my body...)

Shoot me an email on what your progress is! Gota thank you for the good notes to Mike P.

Andrew
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TonyAKAVW
post Apr 3 2006, 02:48 AM
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Lenses will be available fairly soon. My father-in-law is working on a die and will be producing these. Hopefully the plastic he uses will be sufficient to withstand the heat from an HID light. We won't know really until we test them. But because these are truly injection molded, if there is a plastic that can withstand the heat then it can be used.

Look for more details on lens availability in the coming weeks.

-Tony
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Brian Mifsud
post Apr 3 2006, 08:07 AM
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QUOTE (neo914-6 @ Jan 10 2006, 11:56 AM)

I vacuum formed lexan in school but how do you replicate the seal channel? I'm talking to a plastic fabrication company who could vac mold sets of them from a sheet, it still the tooling that takes time/expense...

The Seal channel can be CNC machined. Hit up Mike Mueller. I believe his mill is so equipped.

Also, you can build yourself a "pressure forming" mold, which uses vacuum on the female side, and pressure on the "male" side. This will allow you to press the material into a more detailed mold. You can at least form the "boss" for the channel to be trimmed from.

There are quite a few pressure forming shops in the Bay Area who can help you. Try Freetech Plastics, or Plastic Service Corp (Newark).
The tooling isn't alot of money (under $1000). You can make it yourself, or hit up Mike again!!

The nicest tooling would be aluminum, but you can achieve pretty good results from wood and plaster.
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mrdezyne
post Apr 3 2006, 08:36 AM
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Dow Chemical Co.
Calibre 200-15, 200-22, 300-4, 300-6, 300-10, 300-15
Polycarbonate
Rockwell hardness of R118
Processing temps of 525 to 620 degrees
Deflection temp at 264 lb/in = 263 degrees

Optically clear

Just one option, something to check out maybe.....
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mrdezyne
post Apr 3 2006, 08:40 AM
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WOW! Just realized that was from a 1987 product guide, I'm sure there are many better products for this application by now. I'll find a newer guide and check into something better......
(IMG:http://www.914world.com/bbs2/html/emoticons/wacko.gif)
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cbenitah
post Jun 13 2006, 02:54 PM
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Felix or Tony,
Any progress on the lights?
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