DaveW

Quaz

You don't need to run such expensive tooling to achieve what we wan't. Those prices are for injection moulding - there are more appropriate methods for such limited production numbers. I would suggest vacforming 2-3mm ABS sheet for the reflector and acrylic or polycarb for the transparent cover. These base components could then have any kind of surface finish applied.

Vac forming would bring tooling down to hundreds rather than thousands of dollars, and for this kind of component the lower tolerances won't make a difference.

Alternatively if you are after very fussy finned parts you could stereolithograph individual parts cheaper than injection moulding for such a small run of parts.

Just for info I used to design plastic components for the auto industry (a few years ago now!)

Cheers
Dave

Quaz

Dave,

Huh, I am a little new to this so any advice is appreciated. One of the guys that works here used to work for a couple of plastic companies. He is going to make some calls and doing a little research when he has some time. I currently work for an auto supplier so I do have a few resources I can use here, but I need to know the right questions to ask.

So please feel free to email me if you want to discuss more details.

thanks

vicente

How did I not think about it before!

Stereolithography could be the answer as DaveW says. With a good 3D computer model you can make a small batch of practically ANY shape in a single piece. The resin materials used can be treated and oven cooked for durability.

Quaz

What is the most common model used for Stereolithography. Catia, UG, or ProE? One of the Engineers here will model it for me in his spare time.

Brendan

Kev, Now your talking. I dont know what your saying but, I think I like it.

KBlair

Another large vs. original photo. I only did one side so you could do a before/after with the same pic.

<img src="http://boards.rennlist.com/upload/large-small-lights.jpg" alt=" - " />

DaveW

Quaz

Yeah, I like the thought of stereo lithography too, it will really open up the design posibilities in comparison with other production methods: no need to consider how to get the part out of the tool or bothering with draw angles, any part thickness you like and as many undercut's as you want! Bear in mind that the surface finish can sometimes not be too smooth and will probably need some hand finishing to look its best.

The best file format is .STL , this is specifically for stereo lithography. next best are .SAT or IGES files. But most places will be able to take any file format and convert it as long as the component model itself is designed in a way to be structurally possible.

I've had a few parts made in this way (nothing the size of a tail light though!). Tomorrow I will contact the company I've used before and see what their thoughts are on this.

Cheers
Dave

Shark_gts

Need a refresh here. Is the final design iteration to fill out the cavity with the existing design or go S4-like?

Anyway you look at it tailights are expensive.

Speedhut needed how many cars just to do glow gauges?

Quaz

Here is my thought on what might work in getting this done. The current housing has 4 vertical chambers. Very hard to work with. You would basically have to gut the current housing to do anything with it. Just too much work.

After talking to a couple of people the best housing would basically be empty and the reflectors could then be added to configure it however you wanted. Very modular. Then use LEDs instead of bulbs. That way you could do an S4 style flush or recessed, or some other design.

Ideally I would like to see a few styles protoyped (probably by hand) then get a reaction from the community of what looks best. At that point make a decision on one or two lens desgins and get quotes to build a run of maybe 30. Then based on the quotes establish a price and take preorders. If it is a reasonable amount (like less than $4K) I may fund this myself or with a partner/s. Otherwise deposits would be required to fund the production. Once they are made, sell the inital set to the preorders, then find a vendor to sell the rest. If they all go, make another production run based on demand.

I think there is a demand for a new tail light design for the early cars. There seems to be a few different tastes of what people would like, so a couple of different designs should be prototyped. I don't see the design decided apon until you can look at it in person. So the final in my mind is still a little fuzzy.

As for the S4s, if the first attempt at this were to go reasonable well it could be done again for them. If it turns out to be a major headache, then someone else will probably have to take up the project.

Big Dave

Opinions?

<img src="http://members.rennlist.com/bigdave/large-small-lights.jpg" alt=" - " />

928ntslow

PorKen, KBlair...

Thanks for the enlarged OB lense images. Just what I thought. I really like the way they look enlarged.

BUT, in actually looking at the tail light area, I noticed the contour of the indentation and how the lense will "blowup" to fill the void. It looks as though the reverse light lense will end up being way oversized...not atractive. So, moving the reverse light to a seperate area as previously suggested seems the optimum. That leaves the OB tail lense to have 3 sections...of course if this is a desireable lense.

So it seems at this point all designs are up in the air.

So as asked, maybe we should take a poll in this thread as to what folks would prefer. Take the top 2 choices and run with that for prototypes.

Looks like the choices are:

1)enlarged original style
2)S4 type
3)round LED
4)round ricer type

Keith Widom
SOCAL 928

KBlair

the second one down below is currently my fav

<img src="http://www.thedeathknight.com/928/TailLightsConcepts.jpg" alt=" - " />

but anything to update the looks will be good.

KBlair

For those interested:
<a href="http://www.howstuffworks.com/stereolith.htm" target="_blank">How stereolithography works</a>

PorKen

928ntslow - if the big 'ol 2 color lens was done, the reverse bulb chamber could be rewired to be a brake light...

I like the 2 line indented Quaz, in a thin profile, LED backed design; with lightweight metal brackets mounted to the factory bolt holes (the factory bulb holder and lens would be totally removed).
The reverse light would be a round glass bump where the bumper holes are now.

Along these lines, I humbly present the following wrap-around design for the front:



Chucker - the upper portion would be white, the lower, orange.

Big Dave

KBlair:

That stereolithography is possible the coolest thing I have ever seen.