This has taken too long (for various reasons), but I now have my PIAA 80 Series lamps fitted!
First job was to design the mounting system and get the parts made up. The design consists of four brackets (50mm width) with a curved bar across the front (60mm depth). They're made of 316 grade stainless steel (marine and food grade) to offer increased corrosion resistance, particularly as regards salt on the roads. The brackets were machined from 6mm plate, while the curved bar profile was laser cut ( 8) ) from 8mm plate. Yes, much thicker than might be considered normal.
The brackets started at a standard length, so needed trimming and holes drilling during assembly, to ensure correct fitment. Mounting is via 4 M10 stainless rivet nuts behind the grille, with slots cut in the bumper:
My patented mounting arrangement to apply extra upwards pressure, reduce vibration and keep the threads protected using a short section of thick wall silicone tube and rubber washers:
In situ. As you can see, they butt up to the Allisport intercooler:
The wiring is, of course, an equally important issue. These being 135/90W bulbs, the wiring needs to support a substantial current with minimal voltage drop, so the main loom comprises of a 35/0.30 feed for each lamp. As per the lamps themselves, tinned copper cable is used for added corrosion resistance, and for better reliability, a separate 30A relay is used for each lamp. Circuit diagram below:
The main beam feed is spliced from the back of the headlight connector, runs to the relays, then across the engine bay with the rest of the loom and through the bulkhead to a simple switch that I've unobtrusively positioned below the steering column because it shant be used frequently. The feed is then grounded in the footwell. The H4 bulbs do, of course, offer dipped beams, but I don't intend to use them at the moment, so I've just sealed off the additional wire.
Heat-resistant, braided sleeving protects against chafing and the heat of the FBH.
The job was started last weekend with the inner brackets fitted. The drilling and sawing has been very tough going, having knackered a new set of cobalt HSS drills. PVC foam tape is placed to protect the bumper and grille. The weight of the lamps and bar is designed to be placed on the bumper itself while the rear bolts provide the longitudinal stability.
Double bolts on the outer brackets prevent transverse movement, taking strain off the bumper mouldings.
The bar is mounted via the six M10 A4 stainless bolts, secured with nyloc nuts and dome nuts fitted to protect the threads and finish it off.
The ambient air temperature sensor was previously relocated to the top of the bumper, but has now had to be moved again. I've currently cable tied it to the back of the right hand strut, which seems to be working fine for it, but is subject to review. For now, the additional shield behind the bumper has been left off, but I intend to trim it as applicable and refit it.
The finished job:
As you can see, the bar is designed to match the width and curvature of the grille and bumper slots. "Why mount the lights so close together?", I hear you ask. Two reasons; firstly, one lamp is a spot beam (right) and the other is a driving beam (left), but mostly, because the bar is designed to take two additional 160mm lamps to either side that I hope to add in the future.
The lamps now need to be aligned, and will hopefully get some comparison shots later.
Covers off...
...and on they go...
I hope you've been at least mildy interested, or better still, inspired. Current: Discovery 3 06MY (55 reg) HSE Auto Zambezi Silver Allisport Fast Road Intercooler, V8 Brakes, Silicone IC Hoses, EGRs Blanked, Remapped, De-Cat pipe, FBHIC
Freelander 2 2007 HSE Manual Tambora Flame
Previous: FL2 56 reg SE Manual Black (written off )
Disco 3 06 reg B7S Manual Rimini Red
Disco 2 TD5 Y reg ES Manual Blue - Chipped
Several Discovery 300 TDis
Last edited by Lost for Words on 1st Feb 2016 11:36 am. Edited 1 time in total
30th Jan 2016 6:50 pm
geoffsnook
Member Since: 13 Jun 2014
Location: south wales
Posts: 3169
Very cool brackets i'm sure a few of us would like them Discovery 3 se gone
Range rover sport supercharged here:)
Here are last night's pics - unaltered and with indentical settings:
Standard xenon units:
Click image to enlarge
With the PIAAs:
Click image to enlarge
The signpost at the end of the road is over 500m away:
Makes a big difference. Current: Discovery 3 06MY (55 reg) HSE Auto Zambezi Silver Allisport Fast Road Intercooler, V8 Brakes, Silicone IC Hoses, EGRs Blanked, Remapped, De-Cat pipe, FBHIC
Freelander 2 2007 HSE Manual Tambora Flame
Previous: FL2 56 reg SE Manual Black (written off )
Disco 3 06 reg B7S Manual Rimini Red
Disco 2 TD5 Y reg ES Manual Blue - Chipped
Several Discovery 300 TDis
31st Jan 2016 10:24 am
geoffsnook
Member Since: 13 Jun 2014
Location: south wales
Posts: 3169
Very impressive don't suppose you'd ever be in a position to make a few and sell them on Discovery 3 se gone
Range rover sport supercharged here:)
31st Jan 2016 10:34 am
tayaste
Member Since: 15 May 2013
Location: Chester
Posts: 7633
Brilliant.
They look great. Good work.
Agreed,
I think a few of us would like a set of the brackets.
I did wonder if anyone would ask that. In short, I'm afraid not! Primarily, I fear it would be too expensive for most people to justify (getting the brackets and bar made up cost more than the lamps, though I did get those cheaply), secondly, as the holes all need to line up to a close tolerance they must be drilled during assembly, and lastly, the effort involved in it was surprisingly exhausting - knowing everything has to line up correctly with no second chances. If only I had a workshop and a pillar drill it'd have helped a lot.
I can draw up some diagrams if anyone would like to have a go themselves. Current: Discovery 3 06MY (55 reg) HSE Auto Zambezi Silver Allisport Fast Road Intercooler, V8 Brakes, Silicone IC Hoses, EGRs Blanked, Remapped, De-Cat pipe, FBHIC
Freelander 2 2007 HSE Manual Tambora Flame
Previous: FL2 56 reg SE Manual Black (written off )
Disco 3 06 reg B7S Manual Rimini Red
Disco 2 TD5 Y reg ES Manual Blue - Chipped
Several Discovery 300 TDis
31st Jan 2016 10:53 am
geoffsnook
Member Since: 13 Jun 2014
Location: south wales
Posts: 3169
Worth a try Discovery 3 se gone
Range rover sport supercharged here:)
31st Jan 2016 11:01 am
SpiderBaby D3 Decade
Member Since: 21 Sep 2007
Location: Liverpool
Posts: 1397
That looks a very nice fitting
I have been thinking of extra driving lamps to help when I'm in the back of nowhere and pondering how to mount them.
If you have the time and inclination to draw up some diagrams that would be really appreciated.I see no ships........
For starters, here's the profile of the cross bar:
Click image to enlarge
One thing I would add, is that without specialist equiptment it's very difficult to precisely measure the radius of the bumper and grille etc. I made it approx 2.5m, and the bar was cut to that but it is possibly fractionally too small, but not noticeable (a much larger change in radius only equates to a matter of mm over the segment of the bar). A radius of 2.6-2.7m might be closer but don't quote me on that! Note that both radii are the same rather than parallel, as is the case with the bumber and grille.
I'll have to re-measure and draw the bracket diagram(s) since they were tweaked from the initial design. Other factors, like the length and hole positioning will depend on the chosen spacing etc. I have arranged it such that the brackets are secured in the 50mm space adjacent to where the lights are mounted for the best strength.
Current: Discovery 3 06MY (55 reg) HSE Auto Zambezi Silver Allisport Fast Road Intercooler, V8 Brakes, Silicone IC Hoses, EGRs Blanked, Remapped, De-Cat pipe, FBHIC
Freelander 2 2007 HSE Manual Tambora Flame
Previous: FL2 56 reg SE Manual Black (written off )
Disco 3 06 reg B7S Manual Rimini Red
Disco 2 TD5 Y reg ES Manual Blue - Chipped
Several Discovery 300 TDis
31st Jan 2016 12:22 pm
tayaste
Member Since: 15 May 2013
Location: Chester
Posts: 7633
What size are the Piaa 80 lamps, they look big uns ? They look made for the car
31st Jan 2016 12:50 pm
SpiderBaby D3 Decade
Member Since: 21 Sep 2007
Location: Liverpool
Posts: 1397
Yep, pretty big - 8"/20cm. They're designed for the rallying world, so they have proper steel housings and toughened glass lenses. Current: Discovery 3 06MY (55 reg) HSE Auto Zambezi Silver Allisport Fast Road Intercooler, V8 Brakes, Silicone IC Hoses, EGRs Blanked, Remapped, De-Cat pipe, FBHIC
Freelander 2 2007 HSE Manual Tambora Flame
Previous: FL2 56 reg SE Manual Black (written off )
Disco 3 06 reg B7S Manual Rimini Red
Disco 2 TD5 Y reg ES Manual Blue - Chipped
Several Discovery 300 TDis
31st Jan 2016 1:15 pm
tayaste
Member Since: 15 May 2013
Location: Chester
Posts: 7633
I have a curved light bar I was thinking of mounting there. After seeing yours I might change my mind.
I would recommend so. Current: Discovery 3 06MY (55 reg) HSE Auto Zambezi Silver Allisport Fast Road Intercooler, V8 Brakes, Silicone IC Hoses, EGRs Blanked, Remapped, De-Cat pipe, FBHIC
Freelander 2 2007 HSE Manual Tambora Flame
Previous: FL2 56 reg SE Manual Black (written off )
Disco 3 06 reg B7S Manual Rimini Red
Disco 2 TD5 Y reg ES Manual Blue - Chipped
Several Discovery 300 TDis
31st Jan 2016 3:27 pm
tayaste
Member Since: 15 May 2013
Location: Chester
Posts: 7633
I think you may be right
Although, now seeing yours I may make it interchangeable
You cannot post new topics in this forum You cannot reply to topics in this forum You cannot edit your posts in this forum You cannot delete your posts in this forum You cannot vote in polls in this forum
Allisport Fast Road Intercooler, V8 Brakes, Silicone IC Hoses, EGRs Blanked, Remapped, De-Cat pipe, FBHIC
)
