Originally Posted by satrya
Nice mod. 2 questions:
(1) Why not use the original, trim along the lower edge, and add a small strip of sheet metal for the cutoff? That way, the distance between the lens and reflector bowl won't change.
(2) There is probably a change in the beam width intensity profile when moving the cutoff down (as you indicated); the reflector bowl has a somewhat ellipsoid profile left to right. So, even though the distance lighting is probably improved, the side beam may look different; I'm thinking in the context of the different regions you drew out as projected on the road in another thread.
The sides also seem to benefit from having more intense light at the cutoff, the sides are slightly brighter modded like this. The way the hotspot was on the oem mask is far too low IMHO.
I did not want to retain the oem shield as it would have been more conplicated to actually shape the sheet metal like I want. It is fairly easy to cut the sheetmetal to shape and roll it, tweak the angles by inserting a screwdriver in until you get the best output. Just pay attention not touching the return wire with the screwdriver
Aboutthe pdf, I already have a perfectly scale autocad drawing that prints 1:1 scale on paper, the pdf does too, so if possible to have a format that will not have a chance or shrinking or unscaling it it'd be nice. I'll try a few jpg or other image formats and see what I can come up with. I also added a 100mm x 100mm cross next to the shield template to give a scale reference. I guess that would be enough for someone to achieve a scale printout on any printer (worst case scenario, by trial and error, resize, print, measure, and so on)
Shortandhangry: that's what I figured ou too. The oem shield is thick as a brick, eliminating any possibility of color and also some intensity.
The beam seem to dim as it gets closer to the cutoff, I think because the thickness blocks the light coming from certain angles (it makes kind of a blind spot in light coming from the bowl and passing by the shield if you know what I mean).