Hey guys, I just wanted to post a quick pic of the preliminary light bar design. First and foremost, the optics are TIR lenses by Gaggione, the two large ones are the 67mm LLC56N, 12 degree spot with a XHP-70, or 9 degrees with a XHP-50. The 4 smaller ones are an elliptical 45mm LLC49E, 40 degree wide beam and only 14 degrees vertical beam, it’s a wide flat flood, which is what you want in an automotive light.
The floods HAVE to be the XHP-50 as the 70’s are too big for them. But the spots can take 70’s, and I will go with that as they would both have the same lux (~90,000 candela), only the 70 has a larger 12 degree beam over the 50, so I figured why not.
The heatsink on the back is 350mm x 100mm x 48mm, it has 33 fins (3mm to 1.5mm tapered fins) with a thicker 4mm straight fin on each end. Made by Conrad Heatsinks in Australia.
The LED housing is 15mm wall thickness, there is no point in making it thinner as it has to be machined from a solid block of aluminum anyways. And since this is custom, it would only cost more to do more machining. There is an o-ring trench top and bottom, against the heatsink and against the lense… the front bezel pushes down on the lense, onto the o-ring trench.
The LEDs will be driven at 100%, so 18,000 Lumens combined. They will be the top binned chips so expect pretty close to that number. The drivers will have several modes, so no need to blind people 2 miles away if you don’t need to.
The spots and floods will have individual controls as well, so if you don’t need spots, turn them off, and visa-versa.
Let me know what you think.