project update
Oct 29th 2023
So I have been working on getting the base vehicle for my build to no avail, but as my search continues I have decided to make some progress on some of the other parts needed for the project.
As my jeep will be my rendition of what could have been an early prototype of the jeeps in the movie (In Universe) I am okay with these lights not being perfect for that reason, but I wanted to make them look closer to the real ones than they are now.
Here are my lights compared to the Actual Dick Cepek Fog lights the were used in the movie.
The one on top is the exact movie one and the bottom one is the close one I own.
They are both made by Power which is why I bought them. They are also aesthetically very close, but the design overall is slightly different.
So I decided to make a bezel that looks like the original one to fit mine and other small things to make them more accurate, and I am documenting the whole process.
But before I go into the build I want to talk about the other parts that make them closer to the real ones.
- They have the white wire boot like on the originals.
- They have a similar size and shape to the real one.
- They also have the internal metal reflector like the real ones. (that the KC Hilites don't have)
- They are much cheaper and more available than the real ones.
First I opened the light to get to the metal reflector to remove these two wings on it as the Dick Cepek ones don't have them, they easily came off with flush trim cutters but did require me to squeeze a little hard so maybe a tool like a pair of snips would work better for you.
Next, I put it all back together so I could start 3D modeling the bezel
I Have access to 2 3D scanners the Revpoint "Pop" and the "Mini". So I decided early on in the project to use a 3D scaning to help model the bezel. this way it would be a perfect fit.
but I couldn't just scan it, the surface was too reflective for the scanner to read, So I had to use scanning spray. I used Aesub White, it worked great and was easy to clean off after the scanning was done.
(PSA you don't need a thick coat of scanning spray, 1 coat or 2 will work great just make sure you cover every reflective surface you want to be scanned otherwise the scanner won't see it and it won't be scanned)
While I was letting the coating dry, I set up a turntable and the Revpoint "Mini" scanner to start scanning as soon as it was ready.
I then set the part on the turntable and Scanned away.
I will be honest I did spend a good half-hour or so working to get the best 3D scan. I was having some trouble at first but in the end, I learned a lot about 3D scanning and I got a model I could use in Fusion 360 to model off of.
(I was never able to figure out why the tracking went haywire when it got to the flat side but I was able to change the angle slightly and get at least one good scan)
The next step I took was I exported the final model from the Revpoint software as an .OBJ file to use as a reference in Fusion 360.
I used the scan as a template to make a copy of the shape so I could use it to assist in the design.
(though I did end up using both the scan and my copy to aid in the bezels fit and finish)
Here is a video of the design being modeled. I won't go into how I did it. mainly because I am still learning and may not have done it the best, but I am good enough at CAD for the projects I do.
(If you want to see more detail in the video, try slowing it down and that should help.)
And that's it for now, I am 3D printing the first prototype to see the fitment on the light and will update as soon as it's done.
The hope after that is to design in some clips on the back to clip onto the light, but I'm waiting to do that till I know it fits and I like the look.
I also hope to get them either cast in epoxy or (what I really want) injection molded but I'm not worrying about that yet.
If any of you guys have any tips or suggestions let me know.
Also here are some links to the same lights on eBay if you guys want to do this yourself, I'm planning on when I make the ones for my Jeep either selling some and/or releasing the files.
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