All MetalShaping

All MetalShaping (https://allmetalshaping.com/index.php)
-   General Discussion (https://allmetalshaping.com/forumdisplay.php?f=15)
-   -   Lucas P100 style replica headlamp (https://allmetalshaping.com/showthread.php?t=17659)

dwmh 02-14-2018 02:55 PM

Lucas P100 style replica headlamp
 
24 Attachment(s)
I wanted a small quick project to exercise my wheeling, aluminium welding, and metal finishing. I decided to make LED lamp of similar size and shape to the 12" P100 headlamp as used on Bentleys, Rolls, Jags etc. I found a plastic mixing bowl was close to the shape and size needed, which saved making a buck. I made it in three main segments, all shaped just by stretching on the wheel. These were gas welded together.
The welds were filed then run through the English wheel to level them. I then shaped an end cap which was welded on.

Attachment 45341

Attachment 45342

Attachment 45343

Attachment 45344

Attachment 45345

Attachment 45346

Attachment 45347

Attachment 45348

Attachment 45349

Attachment 45350

Attachment 45351

Attachment 45352

Attachment 45353

Attachment 45354

Attachment 45355


The final part was to roll a step on the edge with the bead roller for the bezel. This also needed shrinking with the Lancaster.

I made a former for the bezel and shaped it in the bead roller and Pullmax type machine before welding it at the joint.


Attachment 45356

Attachment 45357

Attachment 45358

Next was metal finishing and quick polish (it needs more) before assembly with an LED bulb and fitting over a workbench. It is just the right height to hit my head on when I sit down!!!!


Attachment 45359

Attachment 45360

Attachment 45361

Attachment 45362

Attachment 45363

Attachment 45364

cliffrod 02-14-2018 04:34 PM

Looks great. I like seeing the old lamp look preserved. The tri-bar detail of these lights is so iconic. Will the housings be left polished or painted after they are metal finished?

Gareth Davies 02-14-2018 04:49 PM

Nice work David.

Charlie Myres 02-14-2018 05:26 PM

Great idea and a wonderful project, well done!

Cheers Charlie

Fordor 02-14-2018 05:38 PM

Nice project. Love seeing pictorial projects . They inspire me to try different things.

Gojeep 02-14-2018 08:17 PM

That is a great little project. :)

Jim Tomczyk 02-15-2018 11:57 AM

Nice work David, looks the business and much more satisfying than buying one.What tooling did you use on the vibroshear to form the bezel?

dwmh 02-15-2018 02:28 PM

Thanks all for kind words.
I did the post to show that a small quick project could test a few skills. My intention is to leave it metal finished. My previous project was an aluminium hardtop for my E-type Jag, but I soon realised my metal finishing skills were lacking, so I wanted something a LOT smaller to refine them on.

Jim well spotted that my Pullmax type machine is a Vibroshear, I needed to roll the flange round where the bezel meets and holds the glass (polycarbonate) in. I used a male upper that I normally use as a linear stretching die and for the female bottom I used a delrin block with a hollow of the matching shape. The shape was put in with a dremel and a crosscut burr, which breezed through it.
Am I right in thinking that you now own Gareth's Vibroshear?

All the shape for the main body was done on the wheel, by luck I could reach everywhere with the wheel.

The inside could do with tidying up to hide the wiring but with Spring in the air my motorcycle isn't going to ride itself.

Cheers

Oldnek 02-16-2018 09:24 PM

Nice Job David.:cool:

neilb 04-30-2018 10:19 PM

congrats on MSOTM david


All times are GMT -5. The time now is 10:30 AM.

Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2024, vBulletin Solutions Inc.