With the previous headlamp bodge removed we could make up a new loom for each of the headlamps and spot lights. To help removing the radiator we decide to connect via 2 x 4-pin AMP Econoseal connectors, these are ideal for automotive and waterproof.
The cable is 1mm Thinwall rated at 16amps and sleeved with cable heat shrink
New loom installed with integral side light and H4 bulb holder
Notek Farlite Spot Lamp
This Notek Farlite Spot Lamp was originally fitted to my dad's Sunbeam Talbot Ten, he removed it from the car when he sold it and I remember playing with the lamp as a kid in the garage at home. It is great to see it back on a car. It is in great condition, a new bulb and o-ring was all that was needed.
Another part of the car that was due an upgrade are the headlamps. The Sunbeam Talbot Ten was fitted with Lucas Dipping Reflectors. When the main beam switch is operated the nearside reflector dips to the left and at the same time the offside lamp is switched off.
This solenoid mechanism had long since been removed and the wiring bodged to fit conventional H4 dual-filament bulbs that provide both low and high beams. The wiring was never upgraded to take the additional current needed and the Dynamo fitted is unable to provide sufficient power.
The headlight bowl was taken from a VW Polo MK1 / Audi 50. The front glass removed and then sandwiched between a rubber gasket and the original Sunbeam Talbot Ten headlight glass. The net result was unusable as the light pattern was poor and the car battery discharged during use.
Bodged headlamp bowl from a VW Polo
A quick measure showed approximately 7" diameter replacement needed and not really thinking I ordered a low cost replica Lucas 7" headlights with sidelight and H4 bulb holder. I'd assumed the new light would fit under the chrome outer cover, clip into place and I'm all set. Yeah, good ideas and all that!
The 7" headlight is actually smaller than the Chrome outer cover so I needed some kind of adapter to keep everything in place. Could a 3d printed adapter be an option?
3d Printing If you've not heard of 3d printing it really is a game changer for producing 1 off or even small batches of parts. It all starts on a computer, where you design or find a digital model of the object you want to make.
The computer then "slices" that design into hundreds of super-thin layers—like slicing a loaf of bread. The 3D printer's nozzle, which is like a tiny, hot glue gun, then squeezes out melted plastic, drawing the first flat layer onto a platform. Once that layer is finished, the platform moves down just a tiny bit, and the nozzle draws the second layer right on top of the first. The plastic quickly cools and sticks together.
The printer keeps stacking these flat layers, one by one, very slowly, until all the layers are piled up and you have a solid, three-dimensional object you can hold.
Design Not being the creative type I can't take credit for the next steps but a friend designed the adapter using computer software Autodesk Fusion.
The design uses a simple groove to lock the top and bottom sections and secured with 3 x M4 Allen head screws. The outer edge has 4 grooves to take original Lucas fitting clips. The design allows a small amount of rotation to allow you to position the light vertically, once aligned a small bead of Silicon sealant or sikaflex to hold in place.
Autodesk Fusion render of Sunbeam Talbot Ten Headlight Adapter
Printing A basic 3d printer is relatively inexpensive to purchase and allows you to produce parts at home.
The printing filament is supplied on reels and available in a range of different colours and types. One common type is PLA (Polylactic Acid) which is extremely easy to print with. It has good tensile strength but relatively brittle and low impact resistance. It also has a low heat resistance and can deform in hot environments, like a car on a sunny day.
As the adapter will be exposed heat we chose to print using ASA (Acrylonitrile Styrene Acrylate) filament. It has excellent UV Resistance and retains its colour and mechanical properties when exposed to sunlight for long periods, making it ideal for outdoor applications. It offers good mechanical strength, rigidity, and high impact resistance. It is also stable in warmer environments and shows good resistance to many chemicals, water, and oil.
Timelapse video of Sunbeam Talbot Ten Headlight adapter ring being 3d printed. The parts are printed in ASA and take around 2 hours to print
Early Sunbeam Talbot Ten Headlamp Adapter Prototype
Fixing The original lights are held in place using a W shaped spring loaded clip. I was missing a couple from one headlamp and the rest were well corroded. The replacement is a Lucas Headlamp OEM 500291.
Left to right. Lucas 500291, Original Lucas, Amazon knock-off greenhouse glass clip.
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Unfortunately the ones I ordered are shorter and according to the supplier the longer version is no longer manufactured. An alternative is to use a clip for supporting glass in greenhouses, they need modifying but the ones I picked up from Amazon didn't have much spring to them and could be bent with your fingers into different shapes, nothing like the quality of the Lucas items.
We also re-printed the top section at a greater depth and moved the clip location upwards a couple of mm but the spring force was then in the wrong direction and the lamp wasn't secure in the front bezel.
Time to improvise with the 3d printer.
Lucas 500291 adapter to allow for the shorter length of the Lucas 500291 Clip. The clip is curved to follow the shape of the front bezel
Finished Article The adapters allow you take a Lucas 7" sealed beam conversion unit with modern fluted lens and have a higher quality beam pattern and cut off compared to the original lighting on the Sunbeam Talbot Ten.
You are free to choose a lamp with either a curved or flat lens and between Halogen or LED bulbs assuming an H4 bulb pattern and enough power available from the dynamo or alternator.
Front view - Sunbeam Talbot Ten Headlamp Adapter for 7" headlamp
Rear view - Sunbeam Talbot Ten Headlamp Adapter for 7" headlamp
They are available to purchase as adapters or as a complete kit with screws, new clips and headlamps. If you wish to use a branded 7" headlamp they should be compatible, once I've got the car back on the road I'm keen to try a branded lamp as a comparison.
