Vulcan Autoworx Sleepy Eye Kit
 

FIRST AND FOREMOST: THIS IS NOT A GB THREAD!!!!
i will post up a GB once I have everything in order, and have purchased a vendor membership. Please do not ask about price! This will be much briefer than David's original thread, showing just what I have personally done.

Now that that is out of the way, on with the thread.


Thank you to David Hayes for his generosity, letting me duplicate this for our community.


This is a blurry pic of the rod end used in the arm that connects the motor to bucket.

Attachment 674144

the actual arm

Attachment 674145

arm installed

Attachment 674146

Attachment 674147

Attachment 674148

The arm is reasonably easy to install. First you remove the ball on the bucket, this is a simple as removing a nut from a bolt.
Second remove the ball from the mini arm that is attached to the motor. for this remove the mini arm from the motor, just unscrew the nut from the motor. then take the mini arm, and (using an angle grinder or similar) grind the back end of the ball (bolt). just a few seconds is all it takes, then punch out the ball from the rear.
Third, drill out the hole that the ball came out of to a 1/4 inch (this is only slightly larger than the stock hole).

For the reassembly the new arm is used.
First put the 1/4 bolt through the mini arm (so that the threads are on the ball side of the mini arm).
Then put the 1/8 inch Delrin spacer on, followed with the arm. finally threading on the nylon lock nut.
Next reattach the mini arm to the motor with the stock hardware.

To attach the arm to the bucket it is very similar. run a 1/4 inch bolt though the arm, then slide on another 1/8 inch Delrin spacer. Through the bucket, finally using a nylon lock nut to secure everything in place.

There isnt a specific torque requirement here, just make sure it is snug. the purpose of the spacers is to prevent binding of the arm when the motor moves.

To install both arms takes roughly 15 minutes if you go slow.

the following are the brackets that allow you to mount the light modules to the stock bucket. (these are an earlier version, though the final version is only minimally altered from this design.

Attachment 674149

just a different angle.

Attachment 674150

The installation into the bucket is relatively straight forward. First make one cut...

using the edge (that I'm pointing at here), place a straight edge along it. Then continue the line.

Attachment 674151

Attachment 674152

then using the edge perpendicular to the first edge. marking it the same was as the first.

Attachment 674153

Cut a line along the first line, from the intersection of these lines to the low point indicated below. the cut can be made with a number of tools, a rotary tool is likely the best option (please ignore the excess cuts).

Attachment 674154

slide the bracket into the slot and push the bracket into the bucket (it will be snug). once the bracket is in secure the tabs to the bucket using screws.

then install the modules and aim them.

next the shroud install.

The shroud will not be offered in carbon, these are one-offs. Also they will have a primer finish, allowing a the owner to paint them which ever color they would like.
there are a few things that will need to be done before final install. The trailing edges of the shroud (near where the screws that hold on the stock shroud) are approximately 1/8 inch longer than necessary and will need to be sanded shorter to fit (on most). I chose to leave the small excess here to leave room for variation between cars.
additionally holes will need to be drilled to secure the shroud (in the same manner and location as the stock shroud). again the choice to not have the holes pre-drilled, allows for variation between cars. there are marks that show the general location.

Attachment 674140

Attachment 674141

Attachment 674142

Attachment 674143


finally, button everything up and enjoy a safer drive.

subscribed!

Wow. Looks like another quality pop-up headlight upgrade option!

Along with probably many others I should think, I have been waiting for this thread to appear after access to the original 'FD Sleepy Eye HID Conversion' somehow disappeared, (assumedly by mod action?)

Anyway Dan, I for one appreciate your on going efforts and can't wait for the finished product to go up for sale.

As stated on the other thread I am interested in the hardware parts, as I already have the required European lamps from previously failed attempts at doing this kind of thing :blush:

Keep in mind that this kit is designed to work with the specific modules.

Any chance you want to share, in detail, why this project became so covert?

I wouldn't really define it as covert, considering how in depth the first two posts were, i would say its really the opposite.

mmm... can't wait. great job on the write up. can't wait to see this installed

Suscribed!

Me too, I had thought this thread was gone for good and I was just beginning to start mocking up my own version. My black, aggressive fd needs to go sleepy!

looking forward to seeing the end product.

Yes please!!!

Been anxiously waiting for this.

Mike

What kind of lights are installed. Hella 90mm?

Hella 50mm low and 90mm high

Looks awesome - you realise of course by posting the CF one offs that you have, that everyone is going to be asking 'Well, how much WOULD you charge to make them for me in CF?' lol.

subscribed!

+1. set yourself up for failure on that one haha.

Btw, how much would charge to make them in CF? hahaha.

Probably in.

In or making my own.

any pictures of the final product mounted?

How many years until the GB?

^Lol! :lol: but given how long it has been so to get to this point; the question is quite fair

Waited this long, so might as well wait a bit longer for the final product!

Keep up the good work Superdan...

Mike

I have been in the hospital the past 2 days. My wife went into labor 3+ months early and we had our son, 1lb 14oz. So bear with the delays.

Interested, patently waiting for this.

Congrats on the new baby.

Dude... in all seriousness don't even give us a second though you have real important things going on.

My thoughts and prayers are with you and your family right now.

Elliot

(Cant edit)

don't give us a second *thought* not though...

Dan... congrats on your new arrival!

Wow Dan. My thoughts are with the three of you.

As my sleepy eye project started this, I'll chime in but not with much. I'll say the forum has a lot of policy changes it underwent and with the ability for non-vendors to now post in this section of the forum, the thread can now be opened so you guys can have some good product :)

As for the kit, the components are top notch.:icon_tup: Dan took the time to inspect what I did and then found a way to much improve the pieces. His control arm solution is a really good one. The arm gives you adjustability while it is installed on the car, a big plus over what I did which has you removing the arm to make adjustments (this reminds me I need to lower my passenger side assembly a bit).

The brackets work well and with a simple cut can be installed easily. I believe Dan made the final product a bit thicker than the originals so there will be less flex than the ones sent to me for testing. It is a pretty easy job to make the cut, slide in the brackets (they do seat tightly which is what you want) and then you screw them in for extra security.

As for the carbon fiber shrouds, they are on my car and look great. Dan saw them at DGRR and made the suggestion of cutting off 1/8th inch of material from the back edge. He's pretty anal about this stuff as the fitment works for me as is but I'll probably go head and remove the edge so he doesn't bug me about it :) He's also right about keeping some variation for shroud mounting screw hole locations. 20 year old cars have some variation and this area is no exception. To get the proper hole location for mine, I removed the headlight cover and test fitted the shrouds. Once they were in the proper place, I then used the screw hole on the bucket and fit a scribe through it (from the inside out as the shroud covers the hole from the front) to mark a spot on the shroud. I took a small drill bit and then drilled a hole from the inside out on the shroud. Finally I used a larger drill bit to then work from outside in for the final screw hole. The good news here is the screws have a washer based head that covers any slight hole location issues so if you need to enlarge the hole for the correct fit, the screw will cover it.

The lighting Dan is using are DOT legal Hella modules. They cost a little more than the Chinese knockoffs but they provide OEM quality lighting. For the 50mm halogen projector units, Dan is using:

Susquehanna MotorSports - Auto Performance Product

If you want to step up to true OEM HID lighting, you can get these:

Susquehanna MotorSports - Auto Performance Product

I have these on my car and they work wonderfully well but I hear the halogen units are really nice as well.

For the high beams, I believe he's using:

Susquehanna MotorSports - Auto Performance Product

Again, this is what is on my setup and they work fine. Frankly the low HIDs work so well I very rarely ever use the high beams. I'd very much like to see a set of these installed for the highs, if the relay can be worked out to turn these on only as high beams:

Susquehanna MotorSports - Auto Performance Product

The reason I like these is they are a true projector beam and I would guess would provide some pretty awesome lighting. Like I said, if Dan could figure out how to use them only as a high beam unit, I think this with the 50mm projector lows would be ideal and wouldn't add too much to the cost.

Finally, I also believe Dan has come up with a plug and play wiring solution so no need to hack up the stock wiring.

All in all, some great work by Dan and looking forward to seeing this kit become available.

Dan - congrats on your newborn son and I do hope everything is getting better. I can relate and do understand, our son was also a premie.

Family first as always.

Take care and keep up the fantastic work

Thanks for the well wishes guys. And David, thank you for the input and as always it is greatly appreciated.

As for the update, Moosejaw has his set, we had a small issue with one of the shrouds being too wide. My fear is that due to the stiffness of the carbon of this piece (sorry, no carbon is not being offered. We were trying to get Moosejaw a set in time for dgrr, and we had some carbon attempts with defects lying around, so we refinished and primered them, and used those. In the end he couldn't make it so it really didn't matter, lol) it will want to pop the screws out that hold it in place. I have a production quality frp set going to him now and ken at shine tells me that the frp isn't nearly as stiff so even if it was a bit too wide the screws should hold it no problem. The set was sent out on Tuesday (I believe) so I'm guessing Moosejaw will have it at the beginning of the week. After a few tests to check for vibration of the lights while driving, I should be able to start a vendor account at the end of the month.

Please excuse any spelling or grammatical errors, I'm holding my son and typing on my phone.

Just a side note, I believe that the width of the shroud is a flaw in the piece itself, and not the mold. Therefore it should not be a reoccurring issue.

)
This

and this :lol::lol:

loooking goood! no wonder why these arent done... you were busy making babies insteady of headlights!!!:gwink: hahah i kid i kid:) (no pun intended)

lolo, in my defense he wasnt supposed to be here for another 3.5 months

Hahahahahaha

(i forgot to mention congrats!)

Any progress to report on this, Dan?

sorry i haven't kept on this thread lately, huge congrats on the baby! i work in a hospital, and deal with the Neonatal ICU, so to have yours home with you is a great sign. Wish you the best of luck!!

Cant wait to get this kit on, and be able to see at night :P if you need some help, let me know!

also, i'd love a pic or two, even if it isn't finished product. David, i like your lighting options... it's a chunk of change to step up to a true hid, but damn i'd love to...

^ Yep, true OEM HID isn't cheap. The lighting I posted up, with the exception of the projector 90mm units, are what Daniel is using in the kit so you should have superior results.

I know Dan had a few sets out for testing so I am also anxiously awaiting the results.

Dreamweaver, he's still in the NICU, and we have likely another month.

Sorry for the lack of updates, moosejaw has his set, but there is a bit of a figment issue. Its minor and I suspect that when the hardware is screwed in, it will fix the issue. Basically the driver's side is a bit too wide, why his is I don't know. I'm going to get a set out for testing on another car soon, so I will find out for sure what's going on.

Also I have some pics to post in a few minutes, let me know what you guys think. I don't want to release something that people don't have good things to say about it. But I have to realize that it is basically a glorified garage project too.

Attachment 667889

http://s207.photobucket.com/user/sup...cfc4.jpeg.html

http://s207.photobucket.com/user/sup...fb61.jpeg.html

Don't worry about the dead links. I'll get more pics later. I'm done messing with it on my phone.

Attachment 667884

Attachment 667885

Attachment 667886

Attachment 667887

Sleepy eye
 

Is this product going to be released....

That is looking good Dan. Are those shrouds unpainted FRP? Do you have any pics of the light assemblies installed?

A hit of satin black plasti-dip, and they'll look OEM!

David, that is correct. They are unpainted FRP,they would need to be sanded lightly and paint it whatever color the owner prefers. As far as pics with the light assemblies, I don't have any yet. I should have some available pretty soon though.

That is a good idea Peter. I bet that would look really nice. I blinged mine up a bit and had then painted Mazda glossy black. Of course now I am rocking the carbon fiber ones from Dan :icon_tup:

I think you are right Dan, if they are FRP, then they should have some pretty good flexibility to them and should bend in when you screw them in. You could also take a heat gun to them and shape them but you'd need to be careful.