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  #121  
Old July 18th, 2014, 04:32 PM
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Carl Jonsson
1995 NAS D90 #219
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New round of prototypes in. Finally.

So it's been almost two months since Expo and I finally got my next round of samples in. I'm at the mercy of my fabricators here and obviously not too high on the priority list which is why this is taking so long. It's funny how prototypes that are complicated and have more parts sometimes turn out to be the easy ones while the simple stuff can give you unexpected trouble.

So here's what I got... and what changed.

1. Small Headlight Guard.
2. Large Headlight Guard.
3. NAS Rear Lamp Guard.
4. OEM Aluminum Grill.


1. The small headlight guards are ready for production. I moved the mounts of the cross bars from the edge to be centered and plug welded from the back. This worked well and the only thing to improve at this point is the gap in the hole where the cross bars fit. Once that is cleaned up they are done. These will be solid.

2. Surprisingly this is the one that I'm having the most trouble with. The new improvements on this round include fillets where the cross bars meet the frame and triangular trusses to widen and strengthen the support to the mount. The problem with this design however is that I'm asking too much of the material. The span of the bars is asking too much of the aluminum and the bars flex. There is pressure created on the bars inside of where the mounts are and they are very wobbly. I'm not comfortable shipping it this way so I would like to ask a question to those of you who were interested in this design. Would it be a deal breaker to go from a horizontal bar design to a diamond pattern design (As has been rendered up earlier)? To me function and durability has priority over aesthetics. The diamond pattern will allow for a much stable geometry without flex. I may render up and prototype a version and compare.

3. The NAS rear lamp guards turn out surprisingly great considering there was no mock ups prior to this prototype. The mounting hole locations need to be adjusted slightly and they welded up one of the mounting tabs on the right side in the wrong location but other than that these are almost good to go.

4. Same here. I can't believe how good this turned out for first pass without mock ups. The fit is great and it looks awesome. The only issue I see is that its a bit over built. I could do a thinner gauge without compromising the design at all. The other slight issue is that the grill surround actually is curved but I am going to circumvent this issue by making the mounting plates out of a thinner gauge so that the grill can be allowed to flex a little vertically when you mount it. That should assure it to mount flush to the surround. Currently there is a slight gap at the top due to the curvature of the surround.

Overall I'm happy with the progress.

What do you guys think?

Photos next...
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  #122  
Old July 18th, 2014, 04:58 PM
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Carl Jonsson
1995 NAS D90 #219
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Small Headlight Guard

Here's some shots of the second generation prototype of the Small Headlight Guard.
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  #123  
Old July 18th, 2014, 05:03 PM
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Carl Jonsson
1995 NAS D90 #219
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Large Headlight Guard

Here are some photos of the second generation prototype of the Large Headlight Guard.
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  #124  
Old July 18th, 2014, 05:14 PM
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Carl Jonsson
1995 NAS D90 #219
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NAS Rear Lamp Guards

Here are some photos of the first prototype of the aluminum version of the NAS Rear Lamp Guards.
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  #125  
Old July 18th, 2014, 05:25 PM
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Carl Jonsson
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OEM Aluminum Grill Prototype

Here are some photos of the first prototype of the OEM Aluminum Grill.
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  #126  
Old July 18th, 2014, 05:53 PM
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Steve
1993 Defender 110 NAS #472
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Those look great
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  #127  
Old July 18th, 2014, 05:54 PM
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Carl Jonsson
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Thanks.

Needless to say the final products will all be hard anodized black.
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  #128  
Old July 18th, 2014, 05:54 PM
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They do look really nice...any plans for a heritage type grill?
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  #129  
Old July 18th, 2014, 05:57 PM
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Steve
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im in for a grille and front guards

Quote:
Originally Posted by Manimal View Post
Thanks.

Needless to say the final products will all be hard anodized black.
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  #130  
Old July 18th, 2014, 05:58 PM
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Mark Miller
1994 Defender 90NAS #1258
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Carl,

Ann Marie , Scott , and I met you at expo , and I am very interested in your large guards for my NAS 94 d90, and also the rear light guards. I assume they will fit over my square rear lights as well. Also the front guards have 4 mounting holes. My plates only have two?

It was great meeting you and hearing about the unipiper...
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  #131  
Old July 18th, 2014, 06:01 PM
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Carl Jonsson
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Thanks Bill.

The other grill design I am working on is the Diamond Grill but due to extended cutting time resulting from all the detail the cost is very high so I am looking into options. I wouldn't be opposed to doing a heritage grill design but you run into the same problem there. The heritage grill is stamped which makes it flimsy and tooling for stamping is cost prohibitive for me at this point. Like I said, I'm open to ideas, especially if there's enough people asking for it.
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  #132  
Old July 18th, 2014, 06:03 PM
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Carl Jonsson
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Great, thanks!

Small or large front guards?

As described above I'm not quote satisfied with the large ones yet.

These are still in development but I'll put you on the "interested in pre-order" list.


Quote:
Originally Posted by Rover110 View Post
im in for a grille and front guards
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  #133  
Old July 18th, 2014, 06:10 PM
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Carl Jonsson
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Hi Mark!

Of course I remember. Good times.

The rear guard design is based on the NAS rear lamp guard design. If the NAS rear lamp guard design fits over the square lights these should to. I have not yet have a chance to test it (just got these) but will make sure before they ship. These are meant as a direct replacement for the NAS rear lamp guards and should fit into the same holes so no drilling should be necessary.

Are you saying that your front headlight guards only have two mounting holes? There should be four. Its the same holes that the headlamp surround panels use to mount. Mark, what do you think about the large headlamp guards changing pattern from horizontal bars to a diamond pattern? There is too much flex in the bars because I am asking too much of the material. That is why I'm considering changing it to a more stable geometry. This is not an issue on the small guards because of the shorter span.

Quote:
Originally Posted by Greenbull View Post
Carl,

Ann Marie , Scott , and I met you at expo , and I am very interested in your large guards for my NAS 94 d90, and also the rear light guards. I assume they will fit over my square rear lights as well. Also the front guards have 4 mounting holes. My plates only have two?

It was great meeting you and hearing about the unipiper...
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  #134  
Old July 18th, 2014, 06:31 PM
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Carl Jonsson
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Thanks Jeff.

Here he is on Jimmy Kimmel... with flames.

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  #135  
Old July 18th, 2014, 10:14 PM
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Mark Miller
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Oh man, Live unipiper on JK. The best!

------ Follow up post added July 18th, 2014 10:16 PM ------

Carl,


I do like the diamond pattern on the large grills.
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  #136  
Old July 19th, 2014, 08:52 AM
Rover110
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Steve
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I'm thinking small. Is there a side-by-side photo?
will the black be matte or semi-gloss?
I recently had a grille delivered and it is gloss, and I hate it.

Quote:
Originally Posted by Manimal View Post
Great, thanks!

Small or large front guards?

As described above I'm not quote satisfied with the large ones yet.

These are still in development but I'll put you on the "interested in pre-order" list.
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  #137  
Old July 19th, 2014, 09:00 AM
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Carl Jonsson
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I can take a side-by side picture. I will have better photos with them mounted once I get the damn ARB bumper off my truck.

Hard (Type 3) Anodization creates a satin matte finish. Since the anodizing is just a chemical reaction of the surface of the aluminum in order to make it harder and change color, there is nothing added to it so it still keeps the surface texture the same as it were before the process. If they are sand blasted or tumbled they'll retain that surface finish.
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  #138  
Old July 24th, 2014, 01:20 PM
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Carl Jonsson
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Here is a comparison photo.

Quote:
Originally Posted by Rover110 View Post
I'm thinking small. Is there a side-by-side photo?
will the black be matte or semi-gloss?
I recently had a grille delivered and it is gloss, and I hate it.
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  #139  
Old July 24th, 2014, 01:21 PM
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Carl Jonsson
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Hey guys.

Please check out my company announcement.

Thanks!
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  #140  
Old July 24th, 2014, 01:31 PM
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Quote:
Originally Posted by Manimal View Post
Here are some photos of the first prototype of the OEM Aluminum Grill.
Wow that looks amazing. I can only imagine how much work it took to have that machined in aluminum.
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