Had some down time on the rear LED boards while my buddy's 3d printer was repaired and the flow of plastic clips dried up so I worked the layout of the front LED boards.
Seems more interest in the Euro front bucket so I'm starting with that version.
It would be ideal to make a universal board do US and Euro format unfortunately the white running light LEDs have a higher voltage drop than the amber thus 3 white LEDs are in series versus 4 amber LEDs per string. Therefore it's difficult to make a Euro board into a US board.
Here's some 3d drawings of the board so far.
The board has 48 amber turnsignal LEDs and 21 white running light LEDs.
There will be a configuration option with the Euro lights: The amber turnsignal LEDs can be configured to be dimly on for running lights or off for running lights.
Here's what the board looks like now when viewed from the front of the 914.
Click to view attachment Here's a side view of the board. As SirAndy pointed out with the rear lights, the dispersion angle is tight with these LEDs so they must be pointing in the direction that light is intended; that is directly in front of the car. Mounting them perpendicular to the board will not do as the light will be pointed into the sky at about a 45 degree angle.
Click to view attachmentThis pic shows a close-up of the one difficulty with the LED angle that I'm trying to solve. Unlike this pic of the board, the leads will be bent and perpendicular though the board. Somehow the LED has to be soldered about 3/16 of an inch off the board then leads bent so the LED is at about a 45 degree angle.
That's one issue. The second is once the leads are bent, how to take the stress of securing the LED off of the soft solder on the leads. Eventually the vehicle vibration through the LED bodies will wear out the solder and the solder will fail. Somehow the body of the LED must be secured to the board by other mechanical means. Right now I'm thinking about conformal coating or caulking of some sort.
Any ideas on soldering the LEDs 3/16" off the board or securing the body to the board are welcome.
Click to view attachment