[Shadowchaser]

I've been wanting to do this for ages now and finally I've made a start on them


http://www.auld66.dsl.pipex.com/Project/TSI
Marked out using a card template.

http://www.auld66.dsl.pipex.com/Project/TSI
Drilling small holes all around the marked area for the intakes.

http://www.auld66.dsl.pipex.com/Project/TSI
The backs chopped off to allow plenty of cold air to pass through.

http://www.auld66.dsl.pipex.com/Project/TSI

http://www.auld66.dsl.pipex.com/Project/TSI
The intake holes cut out.

http://www.auld66.dsl.pipex.com/Project/TSI
Should let plenty of cold in.

http://www.auld66.dsl.pipex.com/Project/TSI
Edges all cleaned up and smoothed out.

http://www.auld66.dsl.pipex.com/Project/TSI
Protective tape removed (note how I positioned the intakes to fit within the old reflectors).

http://www.auld66.dsl.pipex.com/Project/TSI
There are small gaps either side of the new intakes that will need to be filled and sealed against the rain though.

http://www.auld66.dsl.pipex.com/Project/TSI
I'll use small bits of Foamex and some bridging filler to seal them.

http://www.auld66.dsl.pipex.com/Project/TSI
The old bulb holders were melted away so these need some work on them.

http://www.auld66.dsl.pipex.com/Project/TSI
I decided to cut away the old bulb holder surrounds and I'll make up some aluminum plates to hold the new indicator bulbs in.

http://www.auld66.dsl.pipex.com/Project/TSI
Because I've chopped away where the old indicator bulbs were for the intakes I'm going to fit three white LED's as my side lights like this.

http://www.auld66.dsl.pipex.com/Project/TSI
They will just push in the holes and I'll glue them in place so they can easily be taken out again if any of them blow. The nice thing about using these is if one blows I still have two LED's as a side light!

http://www.auld66.dsl.pipex.com/Project/TSI
While I'm at it I'm removing all the raised lettering from the lenses to make them really smooth as they will be painted black except where the side light and indicators are.

http://www.auld66.dsl.pipex.com/Project/TSI
The lens on the left still has it's raised lettering the lens on the right has been filed and smoothed over.


More to come!



Roland

[James aka Madaboutmx5s]

the master craftsman continues his good work!

Well done Roland. Bet they wil l look great.

[COLINK@JDMPASSION]

Bloody genius you are

[mx5ash]

Nice work Roland, I love the idea of the led sidelights. Keep us updated.
Ash

[Martin...]

Nice one mate...

I always envy people that are capable of making there own things, the only thing i can make is mess.. lol

[neil]

Thats a really good idea, saves alot of cash aswell

Dont forget piccies of the final product

[cleopatra]

Roland they look good

I have some tsi's but I can't make them fit with my nose, so am giving up and was just gonna mesh out the whole light opening and put some kind of bracket with the lights on behind it... this looks much better though!

[Gixer]

Good to have ya back Roland,


Be nice to see how they come out mate.


Did you ever sort out anything with them sunstrips?



Cheers
Mark

[-halli-]

Fantastic idea Roland . I will be watching your progress closely.

[Aaron]

great homebrew modding as usual. look forward to the finished item

[Shadowchaser]

I couldn't get 6 small white LED's so I went for these larger LED bulbs instead.

http://www.auld66.dsl.pipex.com/Project/TSI

They are quite a bit bigger so I'll only use two on each side. I soldered wires to the bulbs for ease of fitting.

http://www.auld66.dsl.pipex.com/Project/TSI

Very bright too!

http://www.auld66.dsl.pipex.com/Project/TSI

I wanted some chrome rings to go round the two side lights and the indicators. These were a bargain at about £10 for the lot from B&Q.

http://www.auld66.dsl.pipex.com/Project/TSI

The area where the incicators are going was covered in two layers of orange translucent vinyl and then a "one way" type silver film stuck on top. The area where the side lights will go had a single layer of the silver film stuck over it.

http://www.auld66.dsl.pipex.com/Project/TSI

As you can see looking from the back you can see the orange vinyl but not from the front. When lit up the orange is visible from the front though.

http://www.auld66.dsl.pipex.com/Project/TSI

Because I decided to use two larger LED side light bulbs I've had to enlarge the outer holes and the middle hole will now be filled in.

http://www.auld66.dsl.pipex.com/Project/TSI

Masking tape stuck over the layers of vinyl/film and marked out for the side lights and indicators.

http://www.auld66.dsl.pipex.com/Project/TSI

I then carefully cut around the edges of each circle and removed all excess masking tape and vinyl.

http://www.auld66.dsl.pipex.com/Project/TSI

Fine steel mesh screen from an old microwave door.

http://www.auld66.dsl.pipex.com/Project/TSI

Perfect for my intakes I thought.

http://www.auld66.dsl.pipex.com/Project/TSI

It's a very fine mesh but still lets air flow through it very easily. Plus it's very strong so will take hits from stones very well.

http://www.auld66.dsl.pipex.com/Project/TSI

The gaps at the ends where the light units are were blocked off and filled and all the edges around the intakes filled with P40 bridging filler to stop water getting in anywhere.

http://www.auld66.dsl.pipex.com/Project/TSI

Primed up to highlight all defects.

http://www.auld66.dsl.pipex.com/Project/TSI

Fine mesh test sprayed with chrome paint.

http://www.auld66.dsl.pipex.com/Project/TSI

Both mesh panels glued in place and the one at the front has a black Foamex template taped to it ready for the edging to be glued in place.

http://www.auld66.dsl.pipex.com/Project/TSI

Edging made from a length of old coax cable glued in place. This will get sprayed chrome along with the mesh at a later date to match the sidelight and indicator rings.

http://www.auld66.dsl.pipex.com/Project/TSI


More to come!



Roland

[Jaydee5]

OMG Roland....you are a genius Can't wait to see the end result

[COLINK@JDMPASSION]

Im astounded by your genius

[Minty]

You really are a clever chap, and sooo much patience!

[Aquilan]

Superb mate!!!

You never cease to amaze me!

Good to have you back on here fella!

[Planet Claire]

This thread is like Blue Peter for adults, that or Playschool and through the round window!!

You make it look so easy Roland. Excellent work and I can't wait to see the final installment .

[AMMendes]

That is excelent.
Good work.

[dob]

Good going man. I always love seeing your mods!

[Shadowchaser]

I did a bit more today.....


http://www.auld66.dsl.pipex.com/Project/TSI
All primed up ready for checking for any defects etc. I later cut away all that excess glue around the edges as much as I could.

http://www.auld66.dsl.pipex.com/Project/TSI
Sprayed chrome.

http://www.auld66.dsl.pipex.com/Project/TSI
The intakes were them masked off and the units painted gloss black. Then the masking tape covering the light areas was removed revealing the silver film underneath and chrome curtain rings glued in place.

http://www.auld66.dsl.pipex.com/Project/TSI
Testing the sidelights.

http://www.auld66.dsl.pipex.com/Project/TSI
I'm not sure why they light up slightly blue but I think it may have something to do with the silver film?

http://www.auld66.dsl.pipex.com/Project/TSI
Testing the indicators. There is a slight light bleed into the fixing holes but I will block that off before fitting the TSI's.

http://www.auld66.dsl.pipex.com/Project/TSI
Perfect indicators. I love them!

I've still got to go over the mesh on both units to prick out any holes that are blocked with paint and there are a few small gaps around the rings that need sealing up but they are just about finished now. I'll post some pics of them fitted soon.


Roland

[Mi5]

Very nice!