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My "Pilot-Ray" Self Steering Spot Light Build

Discussion in 'Builds and Fabricators Forum' started by Focker, Mar 29, 2017.

  1. Mar 29, 2017
    Focker

    Focker That's a terrible idea...What time? Staff Member

    WA
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    Inspired by this video clip that someone posted last year (seen at 2:50). When I commented on the spot light in the clip, Howard pointed out that it reminded him of The Pilot-Ray the Self-Steering Automatic Safety Light | The Old Motor



    More recent, a spot light topic came up and it inspired me to get going on this project.

    I originally considered using little hem joints or tie rod ends found in the fastener section of the hardware store...Really cool stuff. Once I started building the "prototype" I didn't see the need for them or bushings. I'll dab some grease in the pivot points...I'm not at all concerned with friction. There's absolutely no binding and the rod is small enough in diameter that it can't compete with the Jeep's steering system...This I know because during the fab process there was some trial and error.

    After looking at the Jeep's steering components, I decided that the mounting point would be near the pitman arm. I gathered some popsicle sticks and skewers to aid in the mechanics of what my brain was thinking.
    [​IMG]

    I used some scrap metal from around the garage and made a small "drag link". In order for the spot light to pivot vs. having a sweeping motion, I needed a bar mounted at a fixed point. I chose the Jeep's frame side. The bar pivots freely between some washers/bushings on a non threaded portion of a bolt's shaft. This bar will link to the spot light's pivot bracket using another small rod.
    [​IMG]

    Once satisfied with the drag link's function, I welded a nut to the future bracket...This bolts to the Jeep's drag link clamp.
    [​IMG]

    I cut threads on the end of the rod and welded the nut to it, I also added a glob of weld to a washer so the rod can pivot within the finished bracket. When mounting the bracket to the Jeep's drag link clamp, you can pivot it left or right to fine tune the spot light's cruising position before tightening it down.
    [​IMG]

    This is the spot light's mounting bracket. I welded a bar to the bracket to control the light's pivot point. I bought a cheap tractor implement light ($15) for now...Or maybe for good?
    [​IMG]

    Working on the details before bending more rod.
    [​IMG]

    [​IMG]

    [​IMG]

    It was great using the metal strapping to find the sweet spot for the pivot points...This saved a lot of time not having to drill a bunch of test holes.
    [​IMG]

    Final pieces. As for the rods...I'm undecided at this point whether or not to keep the shaft collars (with set screws) or thread the end of the rods and put a regular nut & washer on the inside and a nyloc nut & washer on the ends?
    [​IMG]

    In action.


    Final details, paint and grease should wrap this project up. Oh yeah...Mounting and wiring the light with a relay will help too. :D
     
    Cowboyjeeper, CalicoCJ5, BobH and 2 others like this.
  2. Mar 29, 2017
    Howard Eisenhauer

    Howard Eisenhauer Administrator Staff Member

    Tantallon, Nova...
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    Go Brad Go!

    H. :)
     
    Focker likes this.
  3. Mar 29, 2017
    Twin2

    Twin2 not him 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Virginia Beach, VA
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    so you going with only one light
     
  4. Mar 29, 2017
    PeteL

    PeteL If it wasn't for physics, and law enforcement... 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Hills of NH
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    So fun!
    Now, a gimbal and artificial horizon to keep it level on the whoop-de-doos?
     
    Hellion and Focker like this.
  5. Mar 29, 2017
    piffey263

    piffey263 Active Member

    Medford, OR
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    You saw in the other post that duffer rebulbed harbor freight lights.

    Hella h3 bulbs are $5 on amazon, and 6 inch stainless light is $9. Be a great spot light :)
    I will try this myself when funds allow.


    Keep up the work! I loved that youtube video, and wanted to do the driving light and the swamp cooler.
     
  6. Mar 29, 2017
    Focker

    Focker That's a terrible idea...What time? Staff Member

    WA
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    Yeah.
     
  7. Mar 29, 2017
    Focker

    Focker That's a terrible idea...What time? Staff Member

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    I didn't notice, but I'll look for it.
     
  8. Mar 29, 2017
    scott milliner

    scott milliner Master Fabricator

    Seattle Wa.
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    I have one of those movie projectors. To bad I can't find the movie I made of my go cart. It was a early GoPro movie of me driving around the island where I lived. Great video. Brings back memories.
     
  9. Mar 31, 2017
    AlexCold

    AlexCold Member

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    I was going to say something about how that will work with articulation but you're so close to the draglink pivot point that the change is minimal. Carry on! Great work
     
    Focker likes this.
  10. Mar 31, 2017
    Focker

    Focker That's a terrible idea...What time? Staff Member

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    Possible binding due to articulation was tested and eliminated with minimal effort required. As you surmised, the mounting point was the key.
     
  11. Apr 3, 2017
    Focker

    Focker That's a terrible idea...What time? Staff Member

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    Wired up the light today.
    [​IMG]

    I wanted to be down stream from the 30amp fuse that I installed for the headlight relays. I thought I would try a new idea (at least new to me). I stripped away a small portion of the existing 10amp wire and added a spade terminal.
    [​IMG]

    Soldered.
    [​IMG]

    Spot light relay.
    [​IMG]

    On/Off toggle switch under the headlight switch. I found a mini version of a headlight style switch, but it was garbage during operation...The light would flicker until I found the sweet spot...Frustrating!
    [​IMG]
     
  12. Apr 3, 2017
    Mark Wahlster

    Mark Wahlster Member

    Silverton, OR
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    How much will that light weight mount bounce?
     
  13. Apr 3, 2017
    piffey263

    piffey263 Active Member

    Medford, OR
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    GM choose to do a solder crimp and spliced wire insulation. Not that far off, using a spade terminal.

    I would keep that area ziptied or mounted due to vibration. All honesty its probably fine. Butt connectors improperly crimped is probably more likely to fail.
     
  14. Apr 3, 2017
    Focker

    Focker That's a terrible idea...What time? Staff Member

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    It's actually pretty rigid.
     
  15. Apr 3, 2017
    Focker

    Focker That's a terrible idea...What time? Staff Member

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    The spade piece was soldered into the wire...If we're talking about the same thing?
    [​IMG]
     
  16. Apr 3, 2017
    PeteL

    PeteL If it wasn't for physics, and law enforcement... 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    It's gonna bounce, until it is gusseted or braced.
    Murphy's Law of Prototype Fabrication.
     
  17. Apr 3, 2017
    piffey263

    piffey263 Active Member

    Medford, OR
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    Yes I was,
     
  18. Apr 3, 2017
    Focker

    Focker That's a terrible idea...What time? Staff Member

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    I finally got to do an official night time test run. I'm actually impressed at how cool this is and how it couldn't have turned out more perfect. The spot light goes right where I want it and when it's supposed too (leading the turn just a bit).

    As for bounce and or vibration... None.
     
    Beach66Bum likes this.
  19. Apr 3, 2017
    PeteL

    PeteL If it wasn't for physics, and law enforcement... 2024 Sponsor 2023 Sponsor 2022 Sponsor

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  20. Apr 4, 2017
    Focker

    Focker That's a terrible idea...What time? Staff Member

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    Here's a short clip with only the spot light (no headlights). I didn't get a good shot of the driver's side fender, but you can see how the spot leads the left hand turn.
     
    Arlen, homersdog, GeoffreyL and 2 others like this.
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