"Project Halo" - The 159, Brera & Spider HALO DRL Project - Page 23 - Alfa Romeo Forum
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(Post Link) post #551 of 1445 Old 20-03-14 Thread Starter
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It would be a small package so easy to ship globally. postage costs apply of course
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(Post Link) post #552 of 1445 Old 20-03-14 Thread Starter
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A little update for the die hard...

I have been speaking with a fellow Geek I met at an event I was running at the weekend at a certain underground bunker in London.

Long one short, he is a bigger electronics geek than me and has the ability/kit to manufacture surface mount PCB's. I am currently investigating a run of 24, new design, smaller, better, longer lasting pcb's for the project.

This works for me because it means I don't have to spend 4-6 hours per set making them. It does mean they may be slightly more expensive though, but that is yet to be determined!!

I have also started pulling together a Bill Of Materials for the DIY sets and Coxy has agreed to send me his list of parts as well so we can determine a full DIY cost for the headlights.


2008 159 TI 2.4 JTDM QTRONIC
My Car Details______http://www.jabawoki.com/2014/07/07/alfa-159-ti/
Project Halo Wiki____https://projects.jabawoki.com/index.php/Project_Halo_UK
Project Halo Page____https://www.facebook.com/ProjectHaloUK
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all sounds good to me.

I'd happily take a set of the early stuff (v1) if they're available though.
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I finally got round to fitting one of those 50 timed off relays I mentioned before.

Works a treat

No more off while the engine cranks and you get a enough time to get out the car and see them on at the front before they switch off!

10s delay Durite Delay Off Relay.
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Ok DIY kit scary but no impossible if it's about cost then what the difference or cost of a plug and play set up or even supply and fit
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Ok DIY kit scary but no impossible if it's about cost then what the difference or cost of a plug and play set up or even supply and fit
If you can find someone willing to make you a set, given the effort involved, perhaps double the cost of DIY.

DIY Price TBC!
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been away from the thread a while. After a quick scan over, I take it your only going to be selling the DIY kits now then?
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Yes mate, the cost to manufacture is just too much and the issue of warranty is not possible to solve. So I will provide the controllers for a nominal fee, the rest you buy direct from the manufacturers and between us all we will put together decent documentation (I'll set-up a wiki / project page for it somewhere) and then its down to each of you to sort your own cars. I can warranty the controllers easy. They dont break and if they did I could send you a replacement easy. The rest of the warranties would be with the relevant suppliers then.

Complete sets may become available from time to time if project contributors have the time, and I guess these will go on ebay as an auction. (hypothetically of course).
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Sounds awesome!, when can we look at purchasing and getting started? And how did you go with the new PCB's are they viable?
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Great project !
If you need support to setup wiki/project page somewhere (domain/hosting), feel free to PM me.

I have 2.4 JTDm, and will look forward to got these installed at mine

Thank you
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Originally Posted by kishmish View Post
Sounds awesome!, when can we look at purchasing and getting started? And how did you go with the new PCB's are they viable?
The guy who is looking into the PCB's has first got to translate my design from a "through hole" component based circuit to a full "surface mount" circuit. This will take him a little while as he has to figure out new components to replace the old! It does mean that the boards will become much smaller though, so there is a chance if they get small enough that they will fit inside the headlight rather than underneath in an ABS plastic box as they do now.

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Great project !
If you need support to setup wiki/project page somewhere (domain/hosting), feel free to PM me.
Thanks for the offer Qwerty, its appreciated!

I was thinking of just using a git hub and keeping it all 100% open source.


In terms of an update, I had my Halo's off the car for a while as one of the seals went in one of my development lights, so I spent some time looking into it and seeing how things are holding up. Good news is its all looking just fine! no issues with the circuits or the rings and the headlights come apart much easier using the sealing material Coxy found so repairs are quite easy if you need to!

What this experience has taught me the most is that the Halos have a real effect on the cars presence. Normally if I am "making progress" in the outside lane of the Motorway and come up behind someone who is clearly lost, they just stay there as a rolling roadblock until they wake up and move over.

With the Halo's on and bright its a different story! They literally peel off in front of you and clear a path! its quite amazing! I can only assume the sight of 6 bright circles of light bearing down on you in the rear view mirror creates a "wtf?????!!!" style moment with half the people moving out of the way in fear, and the other half moving out the way to see what crazy piece of exotica is about to pass them

20131127_112436_Richtone(HDR) (2).jpg 20131127_112545 (2).jpg

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Halo project

Hi I joined this forum specifically because I am really keen to install those angel eyes (halo) on my car. Please let me know what the cost & shipping will be to South Africa .thx
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Quote:
Originally Posted by JabawokJayUK View Post
The guy who is looking into the PCB's has first got to translate my design from a "through hole" component based circuit to a full "surface mount" circuit. This will take him a little while as he has to figure out new components to replace the old! It does mean that the boards will become much smaller though, so there is a chance if they get small enough that they will fit inside the headlight rather than underneath in an ABS plastic box as they do now.
Does this mean there's a chance they'd fit on to OEM Xenons?
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Even with the old style boards they will fit OEM Xenons, you just need to find somewhere to mount the controller box.
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Hi Jay

A hypothetical question: If I were to attempt the DIY on my xenons and screwed up the disassembly of the headlight unit, could I replace the xenon HL unit with a standard unit and swap the xenon internals to a standard HL unit?

Cheers.
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I very much doubt it.

If you mess up the xenons you are looking at a like for like replacement @ about 700 per headlight, or buy standard headlights and put after market xenons in them.
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Thanks for keeping us in the loop Jay, I will go by which ever method you recommend is more effective and user friendly to set-up also the method which is more subject low-risk.

Also any suggestions or ideas into how the seals can be improved?... Just wondering how delicate and reliable the overall headlights would be after installations, is there are chance that this could lead to moisture and other problems in the unit over time / general wear and tear? I mean this is not going to interfere with any of the other sensors in the car or anything like that is?

I understand the whole purpose is to refine the project to make it as viable as possible, so sorry to prod you with all the questions

I am just extremely eager to get these bad boys on the spider.
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The seal failure on mine was down to user error

When I assembled the headlights the first time round I didn't use a lot of sealant on one of the headlights and I thought it might eventually let go so I was expecting it.

The methods we have established are all fine and will result in a maintenance free, hard wearing result that you can pretty much forget about, as long as you take the time on the build process!
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I got the first draft of the new controller designs today

They are much smaller!

I have also added an additional opto-isolated input and 1 additional regulated LED output as well as a couple of jumpers to allow for mode selection.

What this means is......

A single controller could run 1, 2, 3 or 4 rings and take inputs from both indicators, main beam and dip beam which means for those 147/156/GT or even BMW drivers, these could be used as a single controller to run all 4 rings on the front of the car.

What is beneficial for us 159/Brera/Spider drivers is that extra 4th input

What I can use that for is the much desired "power-off" routine (theoretically of course). Essentially, as we now use the delay off relay, we get 10 seconds of power when the ignition feed drops, so if I routed the ignition feed to the controllers as the 4th input, I can detect its been switched off in software, and then run a power-down routine, whatever that may look like.

I am now just waiting on costs for the new design as I have asked for a couple of minor changes.
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Ok, costs are back and a pair of controllers is going to be 100, 50 quid a side.

Who is still in?

Current list is:

Zoo 159
Mags159ti 159
Artemis 159
MarcG 159
Alecci 159
Morkey 159
manphibian 159
WiSE 159
kishmish 159
robsterj 159
gakfive 159

m-a-r-k-o 156

Marko, you would only need 1 controller for 4 rings so 50 to you, unless you want 1 controller per side for ease of installation, in which case, its 100 as per the 159/Brera/spider gang.

Let me know who is still in or out and we can look at payment options.

Cheers
Jay
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Jay - what relay is on this? Are we still looking at the daft money 10 sec delay relay or is this in the software now?

Anyway - In (paypal)
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Jay - what relay is on this? Are we still looking at the daft money 10 sec delay relay or is this in the software now?

Anyway - In (paypal)
The controller exclude the relay & power supply unit that would also need to be purchased.

I am working up a full parts list so that there is a better idea of overall cost but that number for the controller is on par with what it would have cost as a supplied / built unit, so you are still looking at less than 500 all in.
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Quote:
Originally Posted by JabawokJayUK View Post
Ok, costs are back and a pair of controllers is going to be 100, 50 quid a side.

Who is still in?

Current list is:

Zoo 159
Mags159ti 159
Artemis 159
MarcG 159
Alecci 159
Morkey 159
manphibian 159
WiSE 159
kishmish 159
robsterj 159
gakfive 159

m-a-r-k-o 156

Marko, you would only need 1 controller for 4 rings so 50 to you, unless you want 1 controller per side for ease of installation, in which case, its 100 as per the 159/Brera/spider gang.

Let me know who is still in or out and we can look at payment options.

Cheers
Jay

You missed me ..........! Although funds might be tight after our other item ! Already have one new headlight , need to find another !
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Ok, I just did a quick draft of the parts list and its about 400 for everything (give or take, ebay, shopping around and delivery charges!:

parts.PNG

All you need aside from that lot are the odd specialist tool like the crimper for CTS100 pins (Coxy found a very cheap one), and the odd tool you probably wouldn't have lying around. That said, even if you had to completley tool up for this job, you are looking at about 130 of tools:

tools.PNG

That puts you at about 550 for a set DIY, or 400 if you have all the right tools already.

Last edited by JabawokJayUK; 04-04-14 at 22:36.
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You missed me ..........! Although funds might be tight after our other item ! Already have one new headlight , need to find another !
Consider yourself added to the list mate!
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