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Would you be interested in purchasing an headlight kit?

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    Votes: 24 80.0%
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Discussion Starter · #23 ·
Sorry to all for the delay. :uhoh:

Serious personal financial issues had put the kit on hold.
Things are turning around, finally, so I am back at it again. :smoke:

I wasn't comfortable making a kit and selling used motors as part of it.
Motors would be coming from everywhere and it is hard to warranty a used part.
The 69/70 setup was pretty good, but the 67/68 setup was pretty involved - lots of pieces.

So............., I changed directions on the motor setup.

I have turned my efforts to make a headlight cover motor that would look 99% stock and use all new parts. Self contained in a "can", like the original vacuum motor.

After digging up a 69/70 vacuum motor and a 67/68 vacuum motor from my parts collection, I got all the measurements I needed and drew the "cans" up in AutoCAD.

I have spent month and months searching for motors that were strong enough to open and close the covers and yet small enough to fit inside the "can". Then finding/designing the nessesary parts and pieces to get the movement needed. Finding controlers to get the 2-way adustable movement required. Each time I would get the technical drawings from the manufacturer and check to see if I could make it fit and operate inside the "can".

I have several 69/70 setups that "could" work, but would require mutiple parts to be tooled and manufactured, thus driving the cost up. Also, the complexity of the gearing design would be a concern for wear/failure over time. Plus, It seemed like everytime I found a motor that would work, it was discontinued by the manufacturer.

This is a slow process. I will find items that I think will work, draw them up and place them inside the can. Get them situated and figure out the mounting. Then I will let it sit wor a week or 2 and roll it around in my mind. Over that time, I usually have an idea on how to improve the design or simplify it. I then go back and tweak it to the new setup.

Yes, lots of "duh" moments. :confused:

I have multiple designs drawn up, all evolving to my latest design. Availablity of parts, manufacture of parts, wiring, assembly and cost allways figure in.

I have finally found a motor that I believe will work and is actually available. It is ordered, but won't ship until late August (go figure).
I have a motor controller with built in limit circuits in hand, along with the required switches.
I am tweaking the frame to hold it all together. Getting it auto-plasma cut, but there are limits to what the plasma cutter can do. These are small pieces I am working with.
The fiinal cover will be black plastic, formed to mimic the original vacuum motors.

It will be a plug-and-play setup:
Unbolt the vacuum motor and bolt the electric one in its place.
Plug the connector into the headlight wire cicuit.
Hook up the fused power wire to the soleniod.
Turn on the headlights and watch the covers open.
Up/down stop adjustments are on top and easily accessable - just a screwdriver needed.

I am currently constructing the prototype.
Using a basic 12vdc electric motor to test the controller.
Getting the frame and pieces plasma cut.
Finding someone to make the plastic "can".

Again, sorry for the long dealy. Still trying!

"If just anybody could make this, everyone would"

Mike
 

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"If just anybody could make this, everyone would"

Don't I know it. I am on my 4th gen now. Making it for your car is one thing. Getting it producable, reliable and affordable is another story.
 

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Kudos to you sir for coming up with a reliable system and having the gumption to display it. The criticism and sarcasm always follows but it is your personal mark on the Cougar end of the muscle car world, which is remarkable in itself. I have done a similar feat with the 67-68 Cougar and I understand it's not everyone's cup of tea but dare to be different and not ready to fork the money over for a setup that is guaranteed to need work of sorts within a couple years. And Rocketman, what part of the Cougar is affordable, reliable, and another story... if I wanted easy I would have bought a Chevelle or Camero lol. I own your mini tach and love it every time I rev my CJ. Thanks again.
 

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Hey CougarKid - any progress update (as I am starting to tear apart my grille on my 68, looking for options to move to electric actuated headlight doors)...

Thanks!
 

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Go to http://www.youtube.com/watch?v=BM3Owvk1Hjc and watch my video. Understand I took the whole headlight assembly off my car to do this. That means the bumper and front valance does to...which aint fun but it is a good time to fix the lights and clean up the grille and even paint if needed. I'm gonna make it a priority to take pictures of the brackets and get them up asap. Workin a lot of ot right now fellas, bare with me.
 

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Discussion Starter · #33 ·
Sorry guys (and gals), I have been side-tracked by my life on this project. I have not given up.
I still work on it sparaticly, as time permits and insparations hit me.

I had a system worked out. It would fit on 67, 68, 69 and 70 models (2 different versions), but used a "used" motor and had a LOT of moving parts. I had great dreams for it, but after carefull consideration, I decided the look, complexity and exposure to the elements was unaceptable.

I changed directions.

Building a new headlight cover motor that would act and look like a factory canister. All the way down to the bolt-in installation.

I did a lot of research and internet searching to find a new motor that was small enough, strong enough, reversable, controlable and reliable. Finding an afforable controller was quite a challenge, too. Minurature eletronic controllers are tuff to find for an application like this. I went as far to design a PC Board to control it - a first for me. It ultimately failed under testing (not the board, the relay), but the learning experience was great. BTW, I am NOT an electronics guy.

I finally found a manufactured controller that would work on my motor and fit my needs and I bought one. It does exactly what I need and ran the motor through initial testing.

I designed and drawn several mounting systems for the motor that would fit in the constraints of the original canister. I tried several different approaches, even having two cut from sheet steel using a plasma cutter. The mounts worked okay, but the motor ran too slow, giving the covers an unwanted lag.

Back to the drawing board, again.

I have a workable, I think, re-design for the mounting and drive system drawn up. I had to re-think the mounting of the motor and add in a system to multiply the speed of the cover pull rod. There have been many itterations of this latest design drawn on computer. Fabrication of the pieces I have designed is an issue. I have quite a few tools at my disposal, but not quite everything I need. I will mock-up in plastic first, then go to steel.

Then to find someone to make the canisters!

You can call all I have written here excuses, if you wish.
You can say I'm lazy, and be partially right.
You can say it's a pipe dream....maybe.

I DO intend to finish this project.....but a GOOD design take time.

Mike
 

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Thanks for the complete update Mike...in my mind it is better to produce a solid, well designed product then put something on the market that ends up being full of modifications after release - especially in this customer base who want the best for their Cats! Keep up the R&D and I look forward to seeing what eventually comes out (even if it is after I implement a different solution, I always enjoy seeing inventors be creative)

Good luck
 

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I just need a good bracket for my Probe headlight motor. Why can't someone fab up one of these and sell copies?
 

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Discussion Starter · #36 ·
I just need a good bracket for my Probe headlight motor. Why can't someone fab up one of these and sell copies?
Search the posts. Someone put up pictures of a probe bracket made from 2 pieces of pre-punched angles.

Mike
 

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