Headlight Guard Design - Defender Source
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  #1  
Old December 17th, 2013, 07:09 PM
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Carl Jonsson
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Headlight Guard Design

I am currently in the process of designing and having fabricated a couple of Defender accessories. First up is a set of anodized aluminum headlight guards that mounts to the existing holes intended for the headlight surround panel. After several MDF mock ups the first aluminum version was water-jet cut, welded and sand blasted this week. I am considering a small pre-production run if there is interest but it won't be cheap.
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  #2  
Old December 17th, 2013, 07:20 PM
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I'm interested. When you come to a price let me know.
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  #3  
Old December 17th, 2013, 07:23 PM
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I like your design as they look more stout than the others that are just for looks.

Interested.
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  #4  
Old December 17th, 2013, 07:28 PM
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Interesting. Have you been able to test fitment when using NAS lights?
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  #5  
Old December 17th, 2013, 07:42 PM
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That's really nice work Carl.
Even the CAD rendering is high quality.
Looks pretty robust. Plays off the lines of the grill nicely.
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  #6  
Old December 17th, 2013, 08:24 PM
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Those are awesome!
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  #7  
Old December 17th, 2013, 09:46 PM
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Very nice design
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  #8  
Old December 17th, 2013, 09:53 PM
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Man, I likey likey!
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  #9  
Old December 17th, 2013, 10:34 PM
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Carl Jonsson
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Thanks Everyone!

The design should hold up well yet be more lightweight than a steel version. This started out as a spare-no-expense, do-it-right and make-it-last kind of a project and it is fabricated here in Portland. OR. I'm planning on using a Black color, Type 3 Anodization process in which the resulting aluminum oxide film is similar in hardness to a ruby or sapphire. Sounds overkill but from experience I have noticed that wind and weather tend to be pretty harsh on products mounted in that location. Unlike paint or powder coat you'll never have to deal with flaking and the subsequent rust issues that follow.

It is designed so that the cross bars interlock like a puzzle to the back plate and are welded in place from the back which helps rigidity and alignment. I am using Solidworks throughout the process and I am actually also in the process of building a 1:1 scaled Defender in SolidWorks to aid with other projects.

Details, images and pricing to follow.
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  #10  
Old December 17th, 2013, 10:37 PM
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Carl Jonsson
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I don't know yet. I have yet to find a test subject as I replaced my NAS turn signal housings with ROW ones.

Quote:
Originally Posted by Rocky View Post
Interesting. Have you been able to test fitment when using NAS lights?
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  #11  
Old December 17th, 2013, 10:37 PM
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Quote:
Originally Posted by Manimal View Post
Thanks Everyone!

The design should hold up well yet be more lightweight than a steel version. This started out as a spare-no-expense, do-it-right and make-it-last kind of a project and it is fabricated here in Portland. OR. I'm planning on using a Black color, Type 3 Anodization process in which the resulting aluminum oxide film is similar in hardness to a ruby or sapphire. Sounds overkill but from experience I have noticed that wind and weather tend to be pretty harsh on products mounted in that location. Unlike paint or powder coat you'll never have to deal with flaking and the subsequent rust issues that follow.

It is designed so that the cross bars interlock like a puzzle to the back plate and are welded in place from the back which helps rigidity and alignment. I am using Solidworks throughout the process and I am actually also in the process of building a 1:1 scaled Defender in SolidWorks to aid with other projects.

Details, images and pricing to follow.
Carl, I'd probably caution against the anodizing...my experience was that it "blued" (or, more accurately, purpled) rather quickly being out in the elements. You may want to test, or even consider powdercoat as an alternative. But they look great!
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  #12  
Old December 17th, 2013, 10:42 PM
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Thanks. I will definitely keep back up options. I think it depends on what type and quality of anodization. My 10 year old Ellsworth mountain bike frame is anodized and the color hasn't changed or faded from exposure. I'll know more when I visit the anodizing vendor.
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  #13  
Old December 18th, 2013, 06:18 AM
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Those look nice, but personally I prefer a variation (for added strength) of the SIII style that also protect the indicator lights.
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  #14  
Old December 18th, 2013, 08:32 AM
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Carl Jonsson
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I have one of those in the works as well.
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  #15  
Old December 18th, 2013, 08:58 AM
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Nice bug catchers! I hate those big ol grasshoppers that are all like green on the inside and leave a giant greasy blob of smashed shell and guts.
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  #16  
Old December 18th, 2013, 09:21 AM
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Quote:
Originally Posted by o2batsea View Post
Nice bug catchers! I hate those big ol grasshoppers that are all like green on the inside and leave a giant greasy blob of smashed shell and guts.
Eh...roadside snack...saves for fuel!
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  #17  
Old December 18th, 2013, 09:59 AM
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These look awesome. Keep us updated when you have a price, as I'm interested also.
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  #18  
Old December 18th, 2013, 12:25 PM
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Carl Jonsson
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Remove a guard and you have a grill to BBQ your grasshoppers on.

Quote:
Originally Posted by Bill Larson View Post
Eh...roadside snack...saves for fuel!
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  #19  
Old December 18th, 2013, 12:39 PM
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Quote:
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Remove a guard and you have a grill to BBQ your grasshoppers on.
would need quick disconnects! but really there might be something there! Kinda like tin foil on a manifold (lamb shank, butter and green onion).
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  #20  
Old December 18th, 2013, 12:40 PM
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Type III should be fine in the open sun. Getting good colors is difficult with Type-III as it will usually have a warm or slightly green cast.

Type II black anodizing can have problems in UV depending on how UV-stable the pigment is, but most of these problems have been solved in the last 5 years.

Overall, anodizing has progressed to the point of being very color stable.
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