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Light Pod Porsche CAD
Light Pod Porsche CAD
Light Pod Porsche CAD
Light Pod Porsche
Light Pod Porsche
Light Pod Porsche

Brief

We were approached by an individual who wanted his own version of an array of LED light units housed within a bespoke carbon-fibre Light Pod that would attach to the bonnet of his car.

Project

We were provided with a picture of a similar design as a guide and told that four individual LED units would be required. We began by scanning the car bonnet, relative to the ground. This allowed us to incorporate the surface form of the bonnet onto the mating face of the new Light Pod, thereby ensuring a perfectly mated fit. We also scanned the proprietary LED units and positioned those relative to the bonnet, ensuring a degree of up/down and side to side adjustability. With the LED units located, we could design the Light Pod and adjuster systems, whilst considering the desire to make a one piece moulding with a return flange for attachment to the bonnet. Consideration was also given to the space required for assembly and for installing and securing the Wiring Looms.

We collaborated with a known manufacturer of Composite items, discussing Mould design, given predicted quantities of Light Pods, and material and lay-up requirements. A Jig to enable the bonnet to be hand drilled was also manufactured with use of the Mould.

We engaged a trusted manufacturer of Wiring Looms, taking their advice on specific hardware and connector types, based on the environment in which the car would be used. A Wiring Diagram was supplied for reference.

We attached in-house the LED units with their adjuster systems and Captive Nuts for attaching to the bonnet. Once assembly was completed, the articulation of the LED units was tested and an initial aim was fixed.

To complete the project, we put together a comprehensive kit of parts and consumables, including all fasteners, drill bits, Loctite and assembly manual to enable the customer to fit the unit to his car.

Result
The finished product was shipped to the customer who in turn installed it on their car and dazzled all around him !
The completed task neatly showcases what can be achieved by working with ES Products & Design, and in turn our trusted partners.