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> LED Foglight Project
Spoke
post Apr 13 2019, 08:45 AM
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Jerry
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The design of an early foglight LED board has begun. mepstein sent me a couple of foglight fixtures to use to design the board. 2 main issues are fitment and heat dissipation. If things work out ok the design should be able to be re-laid out for the later square foglight.

The board will have 8 Cree XP-G3 high power surface mount LEDs with 350ma current each. These will burn about 1W of power with a total power dissipation expected to be less than 10W. Hopefully these will be almost as bright as a headlight.

Each LED will have its own focusing lens. The lenses are Carclo 10192 elliptical 20mm lenses. The light pattern for the 10192 lens is shown below.

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This is the spectral dispersion for the lens.

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Spoke
post Apr 30 2019, 04:10 AM
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Jerry
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The first fully built up PCB. Somehow I managed to not order the correct caps for input and output filtering so had to use smaller lower voltage caps. Original caps should be 100V whereas these are 50V.

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Spoke   LED Foglight Project   Apr 13 2019, 08:45 AM
Spoke   The LEDs will be connected in series and driven by...   Apr 13 2019, 08:51 AM
Spoke   This is what the board looks like right now. It ma...   Apr 13 2019, 08:58 AM
mepstein   I don't understand any of this but it sure loo...   Apr 13 2019, 12:16 PM
StratPlayer   Will you be making these for the rectangle style f...   Apr 13 2019, 01:34 PM
Spoke   Will you be making these for the rectangle style ...   Apr 14 2019, 05:57 AM
Spoke   Will you be making these for the rectangle style ...   May 9 2019, 07:24 PM
mepstein   [quote name='StratPlayer' post='2704950' date='Ap...   May 9 2019, 07:37 PM
DRPHIL914   [quote name='StratPlayer' post='2704950' date='Ap...   May 10 2019, 08:13 AM
Luke M   I'd be in for an early set once you get them d...   Apr 13 2019, 02:11 PM
914-300Hemi   Looks great Spoke.   Apr 14 2019, 06:05 AM
Spoke   This is the fixture I'll use to size the board...   Apr 14 2019, 06:09 AM
Spoke   I printed the PCB front and bottom sides since I c...   Apr 14 2019, 06:15 AM
Spoke   With the spacer attached, now the PCB can sit squa...   Apr 14 2019, 06:21 AM
Tbrown4x4   I'm totally supporting this. I drive at night ...   Apr 14 2019, 07:09 AM
mepstein   I'm totally supporting this. I drive at night...   Apr 14 2019, 10:45 AM
mb911   Really excited for this although currently I only ...   Apr 14 2019, 09:27 AM
mepstein   Really excited for this although currently I only...   Apr 14 2019, 10:33 AM
Tbrown4x4   Good to know! I think I have these on an Amazo...   Apr 15 2019, 05:02 AM
orthobiz   This is great, thanks. I posted some lens pictures...   Apr 15 2019, 03:31 PM
Spoke   This is great, thanks. I posted some lens picture...   Apr 15 2019, 07:49 PM
Mike Bellis   Why not mount the power supply remote in an IP65/6...   Apr 15 2019, 07:22 PM
Spoke   Why not mount the power supply remote in an IP65/...   Apr 15 2019, 07:53 PM
Spoke   OK, the PCBs have been sent to the fab house. Shou...   Apr 16 2019, 09:12 PM
FlacaProductions   I deal with color temp every day. 3200 is tungsten...   Apr 16 2019, 11:08 PM
windforfun   I deal with color temp every day. 3200 is tungste...   Apr 23 2019, 04:02 PM
orthobiz   Why do these need a converter when your other tail...   Apr 17 2019, 12:26 PM
Spoke   Why do these need a converter when your other tai...   Apr 17 2019, 06:44 PM
Morrie   Ideally you would have a converter with no resisto...   Apr 17 2019, 07:58 PM
Spoke   Ideally you would have a converter with no resist...   Apr 19 2019, 02:34 PM
orthobiz   [quote name='orthobiz' post='2706213...   Apr 17 2019, 08:06 PM
914forme   PDBs going to be green or black in the final versi...   Apr 17 2019, 08:22 PM
Spoke   PDBs going to be green or black in the final vers...   Apr 18 2019, 08:02 PM
ClayPerrine   [quote name='914forme' post='2706330' date='Apr 1...   Apr 19 2019, 02:40 PM
Mblizzard   I will be in for a set of squares. Last lights on...   Apr 18 2019, 12:18 PM
eric9144   This is pretty awesome and totally something I...   Apr 18 2019, 01:57 PM
76-914   :popcorn:   Apr 19 2019, 07:16 AM
ValcoOscar   Same here... :popcorn: :popcorn: :popcorn: I s...   Apr 19 2019, 07:33 AM
DRPHIL914   thanks for taking this on! I asked about this ...   Apr 19 2019, 07:38 AM
Spoke   I agree about the comments on color, you don...   Apr 19 2019, 02:39 PM
Spoke   To reduce component and assembly cost, I'm loo...   Apr 22 2019, 06:59 PM
Al Meredith   would it make sense to have two levels, one for ru...   Apr 23 2019, 03:39 PM
Spoke   would it make sense to have two levels, one for r...   Apr 24 2019, 06:50 AM
Chi-town   Just a thought but if you're using a LED chip ...   Apr 24 2019, 09:25 AM
Spoke   Just a thought but if you're using a LED chip...   Apr 24 2019, 11:11 AM
Spoke   Have the PCBs in hand. Will assemble the first boa...   Apr 26 2019, 08:01 AM
Spoke   Here's the PCB under the glass. It will be int...   Apr 26 2019, 08:03 AM
DRPHIL914   :popcorn: Looking good! Cant wait to see the...   Apr 26 2019, 08:06 AM
Spoke   Things like this happen when you set the temperatu...   Apr 29 2019, 01:55 PM
mepstein   Things like this happen when you set the temperat...   Apr 29 2019, 02:14 PM
Spoke   With the correct settings, the oven worked fine. ...   Apr 29 2019, 03:06 PM
Spoke   All lit up with LED lenses. Won't be able to c...   Apr 29 2019, 03:10 PM
Spoke   Printed a jig to drill the heat sink for tapping. ...   Apr 29 2019, 03:13 PM
Spoke   Here's the light pattern with 0.5A per LED on ...   Apr 29 2019, 03:43 PM
Spoke   The glass lens fits nicely with the printed spacer...   Apr 29 2019, 03:46 PM
Spoke   Here's the light pattern with 0.5A with the gl...   Apr 29 2019, 03:48 PM
Spoke   Redesigned the spacer rings so the boards can scre...   Apr 29 2019, 04:49 PM
Spoke   These are the wrong screws. These are #4 x 5/16 wh...   Apr 29 2019, 04:51 PM
Spoke   The first fully built up PCB. Somehow I managed to...   Apr 30 2019, 04:10 AM
Spoke   Started doing some burn in on the first unit. Will...   Apr 30 2019, 04:15 AM
jkb944t   Started doing some burn in on the first unit. Wil...   Apr 30 2019, 06:15 AM
DRPHIL914   Looks great!!! Cant wait to get a set...   Apr 30 2019, 05:54 AM
Spoke   Burned in the prototype for about 20 hours this we...   May 3 2019, 07:59 PM
Spoke   The metal clips will need to be made for each unit...   May 3 2019, 08:01 PM
Spoke   The PCB fits nicely in the case. Will run this for...   May 3 2019, 08:04 PM
Spoke   Not sure how to connect up to the existing wires y...   May 3 2019, 08:07 PM
ClayPerrine   http://www.914world.com/bbs2/uploads_offsite/i.kym...   May 3 2019, 08:50 PM
Chi-town   Can you take a pic of the light output on a wall f...   May 3 2019, 09:58 PM
Spoke   This is the light pattern projected on the ceiling...   May 4 2019, 05:42 AM
Spoke   Got the prototype lit up in the foglight enclosure...   May 5 2019, 02:13 PM
Spoke   Compared the output of the LED foglight to the fog...   May 6 2019, 09:52 PM
Spoke   The driver side foglight is covered up and the LED...   May 6 2019, 09:57 PM
Chi-town   That upper washout will be blinding to oncoming tr...   May 6 2019, 10:48 PM
Luke M   Would the fog light lens make a difference ? I do ...   May 7 2019, 07:43 AM
Spoke   Would the fog light lens make a difference ? I do...   May 7 2019, 05:21 PM
mepstein   Would the fog light lens make a difference ? I d...   May 7 2019, 05:28 PM
Spoke   [quote name='Luke M' post='2711759' date='May 7 ...   May 7 2019, 05:35 PM
mepstein   [quote name='mepstein' post='2711910' date='May 7...   May 7 2019, 06:01 PM
Spoke   I have two early sets I can send you. One questi...   May 7 2019, 06:21 PM
mepstein   I have two early sets I can send you. One quest...   May 7 2019, 06:45 PM
JeffBowlsby   Open the housing and disconnect the wires! No...   May 7 2019, 06:55 PM
worn   Open the housing and disconnect the wires! N...   May 7 2019, 07:54 PM
Spoke   Open the housing and disconnect the wires! N...   May 8 2019, 08:02 PM
Spoke   I'm working on a 911 variant of the foglight l...   May 9 2019, 07:12 PM
mepstein   Early ones are on their way. They are in much bett...   May 9 2019, 07:23 PM
Chi-town   Sorry no fogs on my 75'   May 9 2019, 08:48 PM
Chi-town   Are you going to try different optics or main lens...   May 10 2019, 08:32 AM
mepstein   Are you going to try different optics or main len...   May 10 2019, 08:42 AM
Luke M   [quote name='Chi-town' post='2712683' date='...   May 10 2019, 10:31 AM
Spoke   Are you going to try different optics or main len...   May 10 2019, 02:54 PM
Chi-town   There's a big difference between an old 35 wat...   May 10 2019, 12:09 PM
Spoke   Put the board into one of the fixtures provided by...   Jun 1 2019, 06:52 AM
mepstein   Put the board into one of the fixtures provided b...   Jun 1 2019, 07:02 AM
Spoke   The early lenses are at least 5mm deeper than the ...   Jun 1 2019, 06:53 AM
Spoke   Does anyone make the rubber gasket that goes aroun...   Jun 1 2019, 07:04 AM
Chi-town   914 Rubber makes them   Jun 1 2019, 08:13 AM
Spoke   914 Rubber makes them Thanks. I ordered 2 sets....   Jun 1 2019, 09:13 AM
Mikey914   Ill make sure they get cross listed. We also ma in...   Jun 1 2019, 09:54 PM
Spoke   Finally got the 2nd 914 foglight assembled. This d...   Jun 11 2019, 07:44 PM
Spoke   Here's the 911 foglight fitted in the lens. Th...   Jun 11 2019, 07:47 PM
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