Stand

Stand instructions.docx

On this page you will find pictures, turtorial videos, technical drawings and know-how how to build a working stand for car lighting systems.

There may be many different ways to to this, but overall layout would be always same.

If you are builiding a stand like this, there will be some possibilities to add/remove some functions, but our desingn allows to study passenger car lighting systems without CAN operation at the requiered level in vocational education.

Budget

Lighting stand

Steel tubing ca. 60 kg 53.- Eur

Battery + battery switch + intelligent battery charger 160.- Eur

Lighting switches 150.- Eur

Front and rear lights 170.- Eur

Osciloscope and diagnostic device 800.- Eur

Laboratory power supply unit 160.- Eur

Banana connector wires 200.- Eur

Plexiglass/plastic 30.- Eur

Wires 30m 30.- Eur

Banana connections 60pc 60. -Eur

Additional materials (paint, nuts, polts, fasterners…) 80.-Eur

Additional materials:

Drill set 84.-

Vernier calliper 40.-

Mechanic work lamp 40.-

Measure tape 20.-

Extension cord 5.-

Working gloves 15.-

Welding materials 20.-

Angle grinder discs 20.-

Protective glasses 5.-

Working clothes 80.-

Security boots 50.-

Angle grinder 120.-

TOTAL: 2392 EUR

Please keep in mind that these are approximate prices. Most of them are purchased as used and therefore prices may vary a lot.

1. Preparation

First of all you need 20x20mm steel tubing for stand frame.

We are using different car parts to make this as easy as possible. Lights are from Audi, instrument panel is from SAAB and etc. You can use those parts that you can get easier.

In the future we can add some gadgets to make faults to the system and we have left some empty space on the back of the stand.

2. Welding

We welded the sides first, then added the front of the stand, and the rear.

Things you need:

angle grinder

cutting/grinding disks

tape

measuring tape

marker pen

safety goggles, gloves

welding mask

welding equipment (we use mig/mag)

3. Preparation works for panel

As the frame was welded together, we tried out how the PVC panels fit.

We are using PVC panel because:

-light

-easy to work with it

-looks nice

We cut the panel to fit on the frame, so we can try every thing on and then start painting the frame.

Also we added some small transport wheels so we can easily move the stand around. We bought them from our local craftman shop.

Things you need:

- marker pen

- measuring tape

-knife

4. Painting and installing parts

We painted the frame to metallic silver. We painted the frame because it would start to rust, and looks ugly.

Aluminium rivets

We use aluminium rivets for installing PVC panels on the frame

Things you need:

drill

rivets

rivet gun

Banana connectors

we install banana connectors on the PVC plate

Things you need:

drill

banana connections

Wiring diagram

Also with banana connectors we install wiring diagrams

So after some connectors we installed the main lights. The headlights are from Audi A6 C6, with H7 bulbs in, The rear lights are from Audi A6 C7 wich are LED. We also can put H7 LED bulbs to the headlights to show student the difference on Amps.

We soldered all the wires to the banana connectors, so everything would be organized and steady.

For soldering you need:

soldering iron

solder

steady hand

Working stand only table is still missing.

Stand instructions.docx

Stand instructions

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