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Old 04-02-2008, 07:44 PM
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Default Custom headlights project

I'm working on some custom headlights for V-Twins 77. They are based on L88/LeMans style buckets but they are my own design.

Here's what I came up with, it uses Hella 90mm modules. I'll incorporate Xenon into this for some more candle power and lower amp usage.

The covers will be made out of lexan, contoured on some original head lamp lids. Nothing worse than flat sheets of lexan which do not conform to the body lines.

The design (& quick renderings)









These are the projector modules:





Here's one of the buckets:



Here it is, temporarily in place. Still missing the header bar, I've got a new one now but when I went to bond it in sure enough the hardener of my epoxy putty looked funny and grainy. I did a test batch first to make sure it was still okay and the next day it was still soft and tacky. So, I have to get some new epoxy adhesive first.



It took quite a bit of trimming. The design was made too large on the curved sides on purpose so it can be trimmed down for a perfect fit. There still needs to be a bit of trimming done here and there, especially in the curved parts.



After that I'll have to cut holes, one large and 3 small ones per lamp for the 3 adjusters. They have black sockets that easily snap in place. The xenon ballasts will be mounted on the bucket underside most likely.
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Old 04-02-2008, 11:25 PM
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CAE rocks...

Headlights are WAYYY down on my list.

I will have to do something so until then I try not to do a ton of night time on back country roads on moonless nights.

I do have some experience though... I've a lot of hours VFR at night
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Old 04-03-2008, 01:34 AM
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Looks cool! Can't wait to see the finished result!
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Old 04-03-2008, 11:51 PM
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And for those who wish to retain the pop-up headlights but don't want them to come up as high. Here is a design using the Hella modules, headlight doors open about half way.







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Old 04-04-2008, 12:13 AM
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Quote:
Originally Posted by BBShark View Post
And for those who wish to retain the pop-up headlights but don't want them to come up as high. Here is a design using the Hella modules, headlight doors open about half way.
Now this is exactly what I had in mind for the son's car.......
But using the small rectangular instead of round.
Got anymore pics? ......... Details?
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Old 04-04-2008, 12:52 AM
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The rectangular headlights would be easier because they are shallower. That's less cutting on the doors for the connector than the Hellas, which are pretty long. The other thing I changed is the actuator link. There is a 1/4 steel "leg" attached to the door. It goes over center to lock the door in place. I shortened this link so that it does not come up so far before locking. I have some drawings of what I did. I'll see if I can find them. Of course, you will have to make new bezels.
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Old 04-04-2008, 07:53 PM
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This shows a picture of the stock link (in red) and the new link (in blue). My headlights are designed to come up 4 inches.
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Old 04-04-2008, 11:17 PM
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Thanks, Looks like the mod will be a lot simpler than I first thought.
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Old 04-10-2008, 05:01 PM
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Hear are my headlight trays, modded Ecklers for more modern look....
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Old 04-22-2008, 12:40 AM
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They all look good!Man,I luv to see fresh ideas and new things.
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Old 04-22-2008, 12:48 PM
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Originally Posted by BBShark View Post
And for those who wish to retain the pop-up headlights but don't want them to come up as high. Here is a design using the Hella modules, headlight doors open about half way.
I really like the look of this mod. Do you have any pics of them installed and open? Do you have more info on what you did?
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Old 04-23-2008, 12:59 AM
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Here are some pix of the headlights in the openings. Paint and exterior stuff is last on the list so I have not made much progress.



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Old 04-23-2008, 02:12 AM
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So basically, new Hella units and shorten the link is all there is to it? What Hella's did you use?
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Old 04-26-2008, 03:11 PM
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Pretty slick. Looks cool
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Old 04-26-2008, 03:26 PM
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Quote:
Originally Posted by saudivette View Post
So basically, new Hella units and shorten the link is all there is to it? What Hella's did you use?
The Hella units I used are the same as TT posted above. I did have to cut a hole in the door behind the headlights. The Hella units are deeper and the center of the headlight is now moved up. Shortening the link will alter door open height and still retain the toggle lock feature of the linkage.
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Old 04-27-2008, 10:00 PM
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Larry, did you bolt them down or is that temporary? Hella sells sets of adjuster screws. The screw has a plastic body that bayonet lock into the ears of your lamp unit (you only need 3 per unit obviously) and they have plastic cups that you can put into the frame, that way you can adjust them.
The part # for the adjusters is 9XB 152 977-001 (set of 3 screws, for 1 lamp unit). They fit units 008 193/008 194 (normal & xenon kit)
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Old 04-27-2008, 10:14 PM
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I did get the screw adjuster kit with my lamps. I ordered them from Summit but I don't think they carry them anymore. Right now I have them mounted with poly grommets (for the "swivel") and 10-32 screws into the back plate on the door. Not sure what I will do in the end.
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Old 04-27-2008, 10:19 PM
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If you are not using the screw sets, I'm looking for some LOL. Hella is a German brand but be damned if I can get the screws here. I'm lacking 4 of them. I found them in the UK, the US but here?.... noooooo....they only sell junk here I swear!
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Old 04-27-2008, 10:24 PM
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Looks like it's your lucky day! The ones I have are 152-977-02, ball on one end and hex on other. A plastic bayonet nut on the screw and a split plastic ball socket for each screw. Sound like what you need?
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Old 04-27-2008, 10:36 PM
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Yup, sounds like it. There's a pic of them on pg 1.
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Old 05-03-2008, 04:44 AM
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Default '69 Custom Headlights

I like the ideas that have been expressed in Twin Turbo's thread about using the Hella lamp assemblies, but hadn't considered using the old flip-up headlight assemblies that BBShark is using to mount the Hellas into.

I bought the Eckler kit and put it in, then didn't like it because it seemed to be the only option on the market for custom headlights, so I set out to do my own. A friend of mine in FL had bought a set of aluminum buckets, so when I was there to visit, I took all the dimensional info and plan to make a layout drawing to use 2 headlights with 1 directional in the same housing...have bought the Hella 90mm units (hi & lo) and am looking for a round directional the same size that will look good with the Hellas.

Sorry Guys...I just can't seem to get the hang of posting pictures into the thread...you'll just have to look at my photos.

Last edited by smrtmblues; 05-03-2008 at 02:52 PM.. Reason: Install pictures
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Old 05-13-2008, 11:39 PM
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Quote:
Originally Posted by BBShark View Post
And for those who wish to retain the pop-up headlights but don't want them to come up as high. Here is a design using the Hella modules, headlight doors open about half way.







BBShark, if it's not too much to ask, do you have the dimensions of the headlight lids for your rendering? I am trying to make a hammerform of the lids and if you have the dimensions it would save me a bunch of time.
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Old 05-14-2008, 12:42 AM
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I can get the dimensions from the drawing but they are 68 lids. These are slightly smaller than later. I do have some 69-up lids that I can measure if that would help.

I could measure the curvature of the surface also. I know the back of the lid is a 100 inch radius and the very front is less. There is also a flatter radius from side to side. Let me know what you need.
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Old 05-14-2008, 05:19 PM
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I am trying to make it for a '77 so it would be 69-up. If you could get the dimensions and the curvature that would be awesome. I am going to try to make the hammerform next week but my headlight lids are two states away. Thanks for the help.
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Old 05-14-2008, 08:39 PM
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Here are the radii. The very front of the cover has a smaller radius than the rear. The radius changes where the yellow line is. I will get a dimensioned drawing tonight and post it.

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Old 05-15-2008, 04:35 PM
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Here are the dimensions of a 76 cover:

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Old 05-15-2008, 11:39 PM
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Hi Guys, I like the OEM style flip-up with the Hellas too. The main reason I dislike the originals is they just stick up to high and are like having a Nascar roof flap to slow the vehicle on front. At least lowering them should make them have less drag and not be as ugly either.

I think I will attempt this on my project '80. I know I'm a ways from this but you have to plan ahead and acquire the parts and info long before the piece bolts on.

I still have a set of new Gulstrand lens somewhere around here I got a couple of years ago. I never got to make the buckets, but I did geta template from the original Gulstrand Aluminum buckets before Mike sold the car. So I have options, but I like the flip-ups.

I have information stored from the CF on an electric actuator conversion from a Firebird and had considered using that setup if I went with the OEM style flip ups. Any new and /or easier method on that approach? Jim
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Old 05-16-2008, 03:09 AM
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how do they lock in position if they only open half way?
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Old 05-16-2008, 11:33 AM
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Look at post #7 for the drawing of the shorter link.
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Old 05-17-2008, 04:11 AM
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BBShark, thanks for the dimensions.
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Old 05-18-2008, 03:09 AM
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Quote:
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Look at post #7 for the drawing of the shorter link.

got it thanks thats pretty cool......lots of good engineering going on here
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Old 05-18-2008, 09:13 PM
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That was just what I needed to design a retainer ring for the lexan. I'm going to have this cnc punched and then it's going to be bonded on the underside of the front clip with recessed socket screws throuigh the lexan covers

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Old 03-05-2012, 04:17 PM
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Hey trough the dutch corvette forum they pointed me to this old thread of yours..

very interesting.. did you bring this headlights in real life..? very curious

i know you sometimes look at my thread, but maybe missed the last update of the headlights..

gr, dennis

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Old 03-05-2012, 04:38 PM
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Yes,this car has been running the streets in NL since last year.

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Old 03-05-2012, 05:49 PM
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Quote:
Originally Posted by Twin_Turbo View Post
Yes,this car has been running the streets in NL since last year.

very interesting! If you have close-ups, i would be thankfull.

Looks great. Did you choose not to put on lenses?

gr, dennis
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