Quad headlight project - MDF plugs for vacuum forming

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Quad headlight project - MDF plugs for vacuum forming

Author	Message
Nightfox	Nightfox posted 9 Years Ago HOT Post Details
Group: Forum Members Posts: 2, Visits: 8	Awesome work my friend Looking to do something similar as I have some Hella DE headlights for my Passat B3 1991. The cover's are obsolete from Hella now they're fragile and can break quite easy so looking to either skin mine or make some molds of them Love ya T4 by the way, old skool VWs rock Billy
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TURK	TURK posted 9 Years Ago HOT Post Details
Group: Forum Members Posts: 101, Visits: 662	Thanks Billy, glad you approve ! Ah, yes ........ BMW E30 units, I see the high beam also has the black cross-hairs in them as well, very nice. I did look at using those units for my build in the beginning, but I found them to be slightly underpowered, they were first conceived back in the early eighties. So I decided to use the Hella modular units instead, and the Hella's are only 90mm in diameter so I could just about install two headlight units side-by-side in an aperture originally designed for only one headlight unit. Yeah, I do like my VW Transporter T4's .......... so much so, I've got two of them ! >> Most VW's suffer from major voltage drop on the headlights, making the headlight illumination very poor at night, to the point of being dangerous. I decided I would remedy that and design a quad headlight system with a upgraded wiring loom. The T4 needed a bit of a face lift anyway, automotive headlight and bulb design technology has moved on in the last 20 years, but the T4 hasn't. I'm currently inundated with orders, and I haven't even finished the prototype yet ! >> Unlike most guys on this forum, I'm not fibre glassing or vacuum bagging carbon fibre ............ I'll be vacuum forming my headlight parts. So I've got the headlight mounting brackets to make and the headlight covers. Here's one of my latest headlight mounting bracket prototypes >> I'm currently using the 96Kg/m3 PU foam, and just in the process of applying Pattern-Coat Primer to the plug blanks. My intentions are to create some silicon moulds out of the plugs, so then I can cast Vac-Cast Epoxy resin into the silicone mould leaving me with a solid vacuum forming tooling plug. This is where I may need some help, as I'm now learning the characteristics of the materials. You could say that I've had many failures in the past, but I would see it as, I've found hundreds of ways of how not to do it ! Here's where I am at the moment with the Pattern-Coat Primer application > T4 Quad Headlight Project TURK Tags Plug Quad headlight project Transporter VW T4
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