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D2 - Lights Headlights, xenons, foglights. Everything outside the car that glows

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  #21  
Old 3rd August 2020, 09:47 PM
Audifan Audifan is offline
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I got the L brackets trimmed down but ran into another problem. One of the wires that I fixed gets in the way when trying to reinstall the light assembly.


The wire that's in front as seen in this picture is too thick because of the clear terminal end cover and the heat shrink tube. I ended up breaking the repaired wire .





I tried to trim the rear rectangle hole and found out that it's metal not plastic.
]
A simple fix is turning into a nightmare .
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  #22  
Old 3rd August 2020, 09:55 PM
HPsauce HPsauce is offline
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I forget exactly what I did to mine to get an LED installed, but I think I added on some thin flexible extension wires with a blade connector on one end and a blade socket on the other.
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2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.).
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (A much rarer model than a D2 S8 by the way!) Oh, and a brand new engine at just under 30,000 miles on the factory one!
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  #23  
Old 3rd August 2020, 10:25 PM
Audifan Audifan is offline
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I bought the correct size female spade connector but the problem is that the male end in the light assembly is fairly thick so the female connector doesn't snap together very easily.
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  #24  
Old 4th August 2020, 08:14 AM
MikkiJayne MikkiJayne is offline
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Hmm. Should I just print a complete replacement using LEDs?

Is the glovebox still in the car at this point or have you removed it?
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  #25  
Old 4th August 2020, 02:16 PM
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David's8 David's8 is offline
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Quote:
Originally Posted by HPsauce View Post
I forget exactly what I did to mine to get an LED installed, but I think I added on some thin flexible extension wires with a blade connector on one end and a blade socket on the other.
Ditto. The longer tails made it easy then to remove and change lamps. i also just glued plastic tabs on the rear where the originals had broken off.
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  #26  
Old 4th August 2020, 03:44 PM
Audifan Audifan is offline
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Quote:
Originally Posted by MikkiJayne View Post
Other models of the era used the same clip-in light as used in the D2 for the footwell lights, door puddle lights etc. There is no practical reason why the glovebox couldn't have used this same light too, in fact I may design something to do that instead.
I wonder if the foot well, door puddle lights would fit in the large rear rectangle hole? I'll give it a try later and report back.
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  #27  
Old 4th August 2020, 03:49 PM
Audifan Audifan is offline
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Quote:
Originally Posted by MikkiJayne View Post
Is the glovebox still in the car at this point or have you removed it?
I have it reinstalled but I don't have the front hinge retaining clips installed. I have it this way so I can easily drop down the front part of the glove box to have easier access to the light assembly. The rear hinges were a huge pain to get reinstalled.
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  #28  
Old 4th August 2020, 04:09 PM
MikkiJayne MikkiJayne is offline
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It never occurred to me to take it out by just disconnecting the hinges. I always just unbolt the whole thing.

The puddle lights don't fit. That would have been a sensible and far simpler solution, but since the sadist who designed the glovebox didn't look in the parts bin we have this stupid frangible bespoke thing

My dimensional test model will be off the printer shortly...
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  #29  
Old 4th August 2020, 04:20 PM
MikkiJayne MikkiJayne is offline
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This seems to work ok, although its a tricky one to print with the large overhang.





I will put a 2W LED chip in each flat surface underneath. Those should arrive tomorrow
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  #30  
Old 4th August 2020, 07:46 PM
Audifan Audifan is offline
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I tried to see if the rear foot well light would fit but not even close as it's a lot longer. I pulled out the door puddle light and it wasn't even close as it's too wide and too long.
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Last edited by Audifan; 10th November 2020 at 01:33 AM. Reason: switched picture to attachment
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