Porsche Wind Deflector with Edge Lighting [from CAD, prototyping to finish]

[Nine8Six]

Silver986, I'm aiming to get it out as low cost as possible. Let me estimate the number of man hours that will go into the assembly, BOM and handling and I'll revert back with a final number. One thing sure atm it has to be under $199.95
*******

So... let's get things started shall we. Spent most of yesterday's evening researching for what I thought would have been an easy find (a compatible 5mm wide RGB led strip that is) and ended up wasting nearly half day trying. Just nowhere to be found other than those monster size 1/2" wide strips (5050) that could light up a small town. All that to say; Not An Easy Start lol

What do we do when we can't find hardware? That's right, we DIY here at 986forum. So let's make our own in the exact same size and configs as the previous Ver I so all can interchangeable, keeping the same ultra-light design and all that cool stuff. Here I'm using a 1.2mm thick/2 layers stack with 12x (twelve) RGB 3528 LEDs. Identical to the previous set-up with the only exception of upgrading one color for 16 million others.

Step 1: I'm sending this out to a local PCB manufacturing later on today so this should be in-house in a few days only. I already pick-ed up the LED from my local electronic market and been told by the resident experts that they are the most reliable of them all, wide angle projection, has a diffuser overlay and the most popular by the locals. So let's give them a try and we'll move on to the driver and micro right after, and if all goes well!

I'll update with visuals as I go, same old 986forum DIY theme haha!


^ Circuit consist of 4 sections in parallel with each of those section consisting of 3 LED connected in series.
Requires 12VdC and pretty standard 'led strip', we aren't inventing anything here.


^ Identical size to the previous strip we had so no modifications is required to the existing design! I love doing
pcb but dislike routing those things... 12x 4P led didn't make that task easy on that 5mm wide board :/


^ Final result. Although showing green on the software visual this will be manufactured in black. Just to ensure we
aren't getting that green reflection, I doubt but just in case, same price anyway.

[Starter986]

~ 2 bills? I'd be in.

I'm assuming, correct me if I'm wrong, that the part will be a plug-and-play... and that we'd be removing our existing windscreen and plugging in your part? Or... are we sending you our existing windscreen and you're fabricating on top of that?

I'm thinking if you're selling the complete package one might just sell their existing windscreen making the purchase of your part a no-brainer. You know... offset the expense of the "cool" part by selling the "boring" part.

Thanks!

[BFeller]

Originally Posted by Starter986

~ 2 bills? I'd be in.

I'm assuming, correct me if I'm wrong, that the part will be a plug-and-play... and that we'd be removing our existing windscreen and plugging in your part? Or... are we sending you our existing windscreen and you're fabricating on top of that?

I'm thinking if you're selling the complete package one might just sell their existing windscreen making the purchase of your part a no-brainer. You know... offset the expense of the "cool" part by selling the "boring" part.

Thanks!

Here is what remember from the last time: Fred sent a new panel, LED strip and control box. You would remove the plastic frame from your old panel - so you needed the original wind screen to start. You put the led strip in the bottom of your frame and then install on the new Skybreaker. Then run the control box to some power connection in the center console, followed by connecting the control box to the led - via routing the wire run under the carpet behind the set and the trim around the b pillar.

[Starter986]

Originally Posted by BFeller

Here is what remember from the last time: Fred sent a new panel, LED strip and control box. You would remove the plastic frame from your old panel - so you needed the original wind screen to start. You put the led strip in the bottom of your frame and then install on the new Skybreaker. Then run the control box to some power connection in the center console, followed by connecting the control box to the led - via routing the wire run under the carpet behind the set and the trim around the b pillar.

Gotcha. Thanks!

[Wallace River]

I have to say this was the easiest and snazziest upgrade to my Boxster. I'm not even close to being a DIY guy, but I got this installed and connected no problem. Go for it guys, it's a very cool upgrade that'll make your car stand out.

[Nine8Six]

Originally Posted by Wallace River

Good god this is looking pretty damn good, Ian. I mean the whole set-up, color, yellow rollbar, honeycombs, Porsche crest, jeez man... akeeper. Thanks for posting, good inspiration (and motivation!)

Originally Posted by BRAN

if the plastic is as good as the OEM and the brakelight add-on just optional (turn off/on)...
then count me in as well.

Nope, not as good; ITS TEN TIME BETTER!!! Literally optic-quality clear, no defect, same material (pmma) and professionally coated (scratch/chemical resist). Not all that bad, Bran The brake feature is optional of course, just omit the extra connection.

Our SkyBreaker Club so far:
TTGator, robdelorenzo, Kboggs, Dubaday, maytag, bg305, Troy.Boxster, rick3000, Bran, Jeffrey

*Update*

I've seen that our RGB Led PCB mfg was completed today so once we receive this (late weekend?) we'll be able to prototype on the micro and get drivers working. Also ordered ICs for the driver, we'll try the TI's TLC59731 (single-wire driver) and a ULN2003 Darlington transistor arrays. We are dealing with common anode leds here so not exactly sure who will win the switching job, let's see when we get the parts.

Once we have the RGB and Brightness circuit all dialed-in, we'll move on to an input for the brake signal and wrap this for the electronic part of the upgrade. Should be easy, not!


^ If only I could learn to be as efficient as these guys. They wrap-up hundreds of completed pcb in-a-day these chaps, go figure :/

[Starter986]

Originally Posted by Nine8Six

Good god this is looking pretty damn good, Ian. I mean the whole set-up, color, yellow rollbar, honeycombs, Porsche crest, jeez man... akeeper. Thanks for posting, good inspiration (and motivation!)



Nope, not as good; ITS TEN TIME BETTER!!! Literally optic-quality clear, no defect, same material (pmma) and professionally coated (scratch/chemical resist). Not all that bad, Bran The brake feature is optional of course, just omit the extra connection.

Our SkyBreaker Club so far:
TTGator, robdelorenzo, Kboggs, Dubaday, maytag, bg305, Troy.Boxster,Starter986, rick3000, Bran, Jeffrey

*Update*

I've seen that our RGB Led PCB mfg was completed today so once we receive this (late weekend?) we'll be able to prototype on the micro and get drivers working. Also ordered ICs for the driver, we'll try the TI's TLC59731 (single-wire driver) and a ULN2003 Darlington transistor arrays. We are dealing with common anode leds here so not exactly sure who will win the switching job, let's see when we get the parts.

Once we have the RGB and Brightness circuit all dialed-in, we'll move on to an input for the brake signal and wrap this for the electronic part of the upgrade. Should be easy, not!


^ If only I could learn to be as efficient as these guys. They wrap-up hundreds of completed pcb in-a-day these chaps, go figure :/

Hi 986,

I'm requesting some clarity, please.

Are you selling the entire unit? I pop out my windscreen (store it... sell it... trash it... whatever) and for your purchase price I receive an entire unit? You know, snap it in... "plug" it into some juice... and I'm good to go? In other words, as another poster suggested, I don't have to dismantle my existing part (removing the clear "glass/inserting your "glass"/ snapping it all back together bull****************)?

Also, are you going to be engraving onto the "glass"? You know... Boxster... Porsche... 986... etc?

Thank you for your consideration.

Cheers!