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headlight project

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  • headlight project

    I started my headlight project but didn't get as many pics as I intended to. Takeing pictures always seemed to slip my mind whenever I got a chance to work on it. I was wondering if any one can tell me about how much it should cost to have the retainer cut out of 1/2" alluminum with a CNC router, or if there is a better way ?? I have the alluminum plate and was thinking of doing it myself but I know it would be very difficult with my primative tools.
    The first pics are the shell and the inside retainer that I will weld in when I get my foot control back. The last pic is a drawing of the outside retainer whitch measures 5"x7 3/8". The outside border will be routed 1/16" deep to plug into the shell and the inside border will be routed to 1/8" deep to hold the lamp.
    Attached Files

  • #2
    Hmmm...

    Without access to a milling machine, that's gonna be tough. Do you think you can get a retainer from the aftermarket? Are the headlight buckets aftermarket?

    Comment


    • #3
      I made the bucket myself to my own dementions. I was originally going to make the retainer out of sheet metal too but since I have the 1/2" alluminum plate I figured it might be easyer to have it cut.

      Comment


      • #4
        This is a long shot...

        And it may be crazy or even dangerous but if a mill of any sort is out of the question, you might try a router with rounding, ball, etc... bits. You'll need to make some plywood templates. And I never tried this so I don't know how a router would react to cutting metal. You may need a Variac speed control?
        I might add that little bites with the router would be best.

        Comment


        • #5
          By the way...

          The buckets are awesome! Mind if I ask how you molded the corners?

          Comment


          • #6
            I have routed thinner guage aluminum, about .090" but I was going to try to find someone with a computer operated router or simular equipment to do the job. I just don't have any idea of how much money it would take to get it cut by those means.

            Comment


            • #7
              Hey Pete,

              those look great so far .....good job
              I hope you get it all worked out.

              good luck.

              ........Richard

              I work with a guy that has a cnc machine at his house and is allways looking for some side work. maybe you could go to some machine shops and ask around and see if some one would be willing to help you out.
              also the guy at the local steel suplier knows guys that do that kinda stuff,
              you may be suprised the people he knows.....I guess just try asking around

              Comment


              • #8
                Originally posted by Richs
                The buckets are awesome! Mind if I ask how you molded the corners?
                I had a freind, who owns a lath, cut cut a punch and die for me. I put it in a wood vice to press it. I'll get some pics of it to post.

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                • #9
                  Yes, I suppose that would be best. Hopefully you'll get an idea of the kind of money involved from one of the other members...

                  Comment


                  • #10
                    Originally posted by Richs
                    The buckets are awesome! Mind if I ask how you molded the corners?
                    Here is some pics of the punch & die set I had made and my woodvice/metal press.
                    In an earlyer thread I showed the radius corner jig I made for my brake. I'll look that up and post a link to it. I cant remember what I titled the thread.
                    Heres the thread on the radius corner attachment I made for the brake.
                    http://www.millermotorsports.com/mbo...ead.php?t=4993
                    Attached Files

                    Comment


                    • #11
                      Hey Burninbrair,
                      If I can be of any help let me know. I'm in Penn alot (The Scranton area). I will be in western Penn soon also. We have 6 CNC Haus mills and in the next week or two were putting in a new dynamic water jet. If memory serves your kinda close to Scranton. I will be happy to pick up and drop off anything that you need to have cut. Of course we always have ups.
                      Let me know,
                      Bulldog

                      Comment


                      • #12
                        Thanks Bulldog ;
                        I need to fix the personol info on my posts, I thought I had S.W. Pennsylvania on it. I'm about 50 miles south of Pittsburgh. On monday I'm going to start makeing some phone calls and if I cant find any thing local I'll be in touch, but I'm sure theres got to be some one around here that can do it.

                        Comment


                        • #13
                          A little update on the project. I made the springs to hold the headlight snug. It took a while to get the tempering right but I finally got it. I tried useing mild steel and stainless first with poor results. I ended up useing the spring clips from a cheap socket organizer, the ones that have the clips on a bar that you push the sockets onto. I guess I should have took a pic of that but I'm sure every one knows what I'm talking about. First I had to aneal them so I could work with them whitch prooved to be more dificult than expected. They are so thin that I had to use a torch to cool them, otherwise they cooled so fast they just retempered. After drilling and shapeing them I retemperd them then anealed them to springs by coating them with oil and burning the oil off.
                          Welding down the #6 stainless nuts did'nt go as well as would have liked either, the practice ones went great but I started shakeing real bad on the real thing, took my medication and that helped. I got 1 out of 4 that I'm really happy with.
                          I'm still waiting on the machineist to cut the retainer. He's been really buzzy.
                          Attached Files

                          Comment


                          • #14
                            This is the tripple tree cover witch will be part of the unit. Its made out of 12 guage mild steel. I laid it out on the computer and spray glued the pattern down. Not haveing a bandsaw or plazma, I cut it out with a sawzall and my grinder. Its to thin to get a clean cut with the OA torch, I have the smallest tip available for it but its just too hot, 1/8" is the lightest material I can cut somewhat clean, it does best on 3/16".
                            Drilling and tapping the holes in the tree was adventuresome. It was difficult to rig it up strait with its odd shape.
                            Attached Files

                            Comment


                            • #15
                              Looks Great Pete!
                              That's some fancy clamp work ya got going on there!!!
                              I'll try to get your fender parts on the water jet soon. We were backed up with wore before we even got it hooked up.
                              Bulldog

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