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Discussion starter · #41 ·
Think I've got the boards finalized/laid out for the tails now; only part that is an issue is where the tails curve down at the end (you'll see in the pictures).

I printed the boards out so I could figure out the layout and everything. I'm pretty happy with it; they came out perfect and everything is the right size and lines up.
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I meant to pick up some Bristol board so I could cut some templates but forgot too. I then saw the Popsicle sticks I had kick around and had an idea.
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Since the paper wouldn't flop around now, I laid out the board into the housing.
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Here's the corner I'm talking about. I'm going to have to draw this in CAD and work with it in there.
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I should have all the boards drawn by the end of the weekend! Cannot wait!
 
Discussion starter · #42 ·
Alright, it's official the boards are all drawn.

I'll get some boring number out of the way first thing.
The tails lights will have 138 LEDs per side for brake/marker lights, 66 LEDs per side for turn signals and 147 LEDs for the center section.
The tail lights will pull 2.8A and the center section pulls 3.43A. Everything is voltage regulated to 9V.

I've spent hours and hours on the AutoCAD drawings for the boards. A lot of times I'd print something, cut it out and test fit it. I'd not any changes needed make them and try again. Here's a picture of this process:
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The center section and bumper markers where by FAR the hardest for me to draw.
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I called a local Industrial supply place this week and found out they had 1mm drill bits in stock so I went and got a bunch. Check out how small these things are!
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I also picked up a Dremel Work Station which will function as a drill press.
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I need to order more PCB boards, resistors, etching supplies, etc.
I'm also trying to contact the person I originally bought my PWMs from as I'm doing something different and can't use them now. If I can't get a hold of them I'll have to design my own.
I'm also working on the details for my sequencers (all my turn signals will be sequential) from another HIDP member.

That's it for now!
 
Discussion starter · #45 ·
Other than the ones you plan to use for your reverse lights, do you not need heat sinks to get rid of the heat for all the other LEDs?
This is the reason for making my own boards vs perf board. My boards will have big copper traces which will help keep the heat down on the LEDs. Plus I'm only running the brakes/markers at 9Vs so there's less heat generated then if I had them at 12V.

All turn signals will be at 11.5-12Vs.
 
Discussion starter · #46 ·
Got my el cheapo LED driver in from China this week. I finally got to play with it tonight.
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I then hooked it up to the Cree XM-L to see if it worked right.
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I then hooked my Multimeter up in line to check the current flow.
Here we are just starting off at 300mA.
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Then 700mA (wow is this bright!).
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Then I cranked it to 1300mA (OW my eyes!)
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I wish my camera was better because man are these things bright! My camera can't quite catch it.

Here's some video of me messing around with it.


Order the parts needed for my PWMs this week. I've got the rest of the stuff on the way for etching my boards on the way.
 
Discussion starter · #50 ·
That's a really freaking bright LED... :D
It's crazy how bright it is!

Curious, what do you think the difference is in draw on the electrical system when comparing the factory setup with ALL lights on vs this?
I'm not sure. I'd have to know what filament bulb drew when running.
According to the calculations I've made (need to test in the real world for true numbers) each tail light will pull 2.8As and the center section will pull 3.4A.
Once I get the boards done I can take some real measurements.

WOW thats awesom! So are you going to try an replace every light you can?
Yup, everything will be LED at some point.
 
Discussion starter · #54 ·
I had to make some adjustments to my CAD drawings so I decided to take some screen shots and post the boards up. I was hesitant to do this at first I'll be honest; I didn't want someone to copy it all and be able to have their own boards. However the boards/drawings are not to scale in these photos and there are no measurements so it will be difficult to duplicate. Plus I intend to copyright them.

Bumper Turn Signals/Markers
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Headlight Turn Signals/Markers
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Rear Tail Light Turn Signals
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All the turn signals are sequential and controlled by a microprocessor; they are ground switched hence the common power rail on the top of the boards and individual grounds.

Here's the center section boards.
Sides.
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Lower.
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Finally here's the Brake/Marker boards.
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Last things I need to start soldering the boards are on the way.
Still working on the PWM stuff, I need to order some parts and build some things on the breadboards to see what works.
 
Discussion starter · #56 ·
Nope.

These will be brighter and last longer then 90% of the LED bulbs on the market.
The issue with what's out there is they use low quality LEDs and no voltage regulation. Voltage regulation is a huge thing; a car's electrical system can be as low as 11V (dead battery technically) to 14.5V (or higher if there's an issue). This can quickly destroy an LED that isn't protected by Voltage regulation.
Resistors are not a replacement for voltage regulation.

Wait until I get some boards built and I can start building my power arrays.
 
Discussion starter · #57 ·
Last pieces of the puzzle have arrived today.
20 sheets of Press N Peel Blue from Dipmicro. The Kester 60/40 .031 solder and flux pen are from the local Electronic place.
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Another 10 6x4 single sided and 2 big (I forget the dimensions off hand) double sided copper clad boards. The big ones will become my PWMs and power supplies.
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Huge order from Digikey. Paste flux (in the silver cooler bag), PWM parts, SMD resistors, etc.
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ABS Plastic sheet, I'll be cutting with down to enclose my center section again once I figure out how deep I need to make it.
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My etch tank (Rubbermaid Cereal bin), Hydrogen Peroxide and Muratic Acid.
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I printed off all my boards so I could test them out in there housings to make sure everything is perfect before I start soldering them. I'm going to start with the tail lights first. Only thing I think is going to be a pain is the sides of the center housing; the lower curved board. This is such a weird shape, I'm going to trim the paper and see what happens.
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w00t!
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I didn't screw it up too much, had to make some touch ups with a Shrapie. Most of my issues were caused by my printer not wanting to feed the PNP so I just taped it to a piece of regular paper and it worked perfect!

I started drilling some holes too. This is a tedious task; I'm going to get both main tail light boards done tomorrow and into the etch bath.
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I need to do something with the front of the PCB, either paint it or some chrome vinyl.
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Also added some text which is backwards, not sure how to mirror it in CAD.
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