Making POP-UP Headlights for Our Supercar! (Project Jigsaw Ep. 50)

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This week we continue Project Jigsaw, our 1960's inspired supercar project based on a Porsche Boxster. We figure out headlight placement, then begin designing complex pop-up headlights! Come along as Tony and Ryan problem-solve the complex engineering behind this project, and take jabs at each other all along the way!
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[@myopinion69420]

I love popup headlights, I hate that they disappeared.

[@dudleym1956]

I see what you did there

[@throttleout3463]

Yeah but apparently some guy behind a computer said they were more of a pedestrian shovel (scoop) than cool so no mas.. but wanted to make mine wink like the cool kids lol #superflex

[@UKBUILT]

Yeah they are iconic 😍 The pop downs on the diablo restomod are cool tho 👍

[@Gentleman...Driver]

@@throttleout3463 We cant have nice things. 😞

[@johnnyg9804]

My buddy and I represent the pop-up headlight crew('91 BMW 850i & '91 Acura NSX) We thank you. ❤❤❤

[@thechadwick22]

Also shout out to your videography. Night and day from the first vid with the new team, and it's awesome to see you guys both cranking at the same time vs the old setup. Major upgrade.

[@GooseGosselin]

Awesome to see the cut away shot from clay to aluminum, editing was on point through out! Appreciate you showing how much work goes into every detail and how it all doesn't come together automagically.

[@myopinion69420]

my stupid ass thought you were cooking those eggs on the body of the car for a second

[@bonovoxel7527]

oh you're not alone bro

[@HitokiriRaiden]

I love that yall are going through the trouble of pop up headlights they just look so nice when done right. Cant wait to see this thing ripping around.

[@GabrielGBR1933]

Automation 2 lookin fire 🔥🔥

[@i.am.adrian]

The connectors inside the headlights be like ‘uhh…life, life finds a way.’

[@HomeBuiltByJeff]

I get the same comments about using the track pad for CAD. I am quite comfortable with it, and who wants to looks after a mouse? The food, the smell....

[@CrucibleCoachworks]

This man gets it. 😆

[@tobyz.3452]

Recess them and be done with it. (GT40 looks great) Pop-up just adds another thing that could go wrong over time.

[@Wonkoman42]

Came here to say this. Knew I wouldn’t be the first.

[@TheNorthernmunky]

Engineering wizardry as always. Superb

[@thechadwick22]

Can't be easy taking a sawzall to a newly formed panel. Always a blast watching you both work through engineering problems but if I'm 2nd hand cringing, I can't imagine how sphincter clinching it must be to cut up your hood panels in person. It's looking great! Thanks for my weekly shot of garage hijinx viewing!

[@petrolheadJJ]

Many project Binky followers watching these?

[@albertofavalelli6361]

I miss the "need a bracket" 😢

[@charleswashington1635]

You could try attaching the scallop off cut to the light assembly that way everything would be flush when the light is retraced. Looks good though

[@biglakehotrods381]

Heck yeah! I love the pop ups!

[@ferrariguy8278]

I'm kind of surprised you didn't arrive at a Pop In solution. The light woudl be effectively hinged at the very top edge, then swing inwards at the bottom meaning only the bottom would need to be scalloped. Again - different engineering challenges but woulda also-been-cool.

[@EternalGamingNet]

Great problem solving! Fun video as always.

[@BenjaminHoffmann-df5hn]

We need more robot-Ryan with Tony's robo-voice. ( Make it a bit like HK-47 from KOTOR ^^ )

[@DataRew]

Ok, I REALLY dig the editing/scoring/etc. on this one! It's not like Ryan's style, but it's as good! Fucking keep it up!

[@omdcarsandairplanes]

Pop down headlights, sweet! Subscribed!

[@Oehmmmm]

It's that time of the week again. Nice!!! :D Greetings from Switzerland.

[@1drwnd.porsche]

Amazing ingenuity….great work fellas!

[@tomschultz2833]

I have been guilty of using ring connectors for spades 😅 I have also used morimoto projector beams. They were awesome!

[@carbongecko]

I have always loved the 944t and it's pop ups, can't wait to see your guys plan, build and execution.

[@richeeze]

Simply lovely.

[@josephpressinger1525]

Love the 993 lights. Have you considered a cross between the motion of the pop up on the nardone 128 Porsche and the housing style of the Lamborghini Miura’s lights?

[@JonFukuda]

The variable fulcrum jig was genius! Nice problem solving skills!

[@asciimation]

Mechanical dip mechanisms aren't new. Rotax lamps (maybe some Lucas too) from the 20s/30s on old UK cars used a system where when the lamps were dipped the offside one would turn off entirely and the near side reflector was moved diagonally by an electro magnet to point in a different direction. The lamps are stand alone units and look the same externally but they are different inside, the NS one having a slightly smaller reflector to allow room for the dipping mechanism. Of course this isn't legal these days so on the car I am making I need to use different bulb holders inside the lamps to take dual filament bulbs (or LEDs most likely).

[@NoReverse77]

Printing the inside part to hold the bill more to the middle of the light will allow you to make an angled sheet metal cover so when the light flips up the metal is even with the body. Since it’s a projector it doesn’t need that chrome backing. High temp black will work perfect and the light being lower in the housing will be a bit more periodic correct.

[@tomthompson7400]

very neat bit of scanning and printing , its nice to see things that work.

[@BMW3.0CS]

Guys I don't think you need to scallop the fender because the projector is at the top of the lamp unit not the bottom. I don't think the fender will interfere with the beam image

[@evgenysavelev837]

You could probably make the headlights pivot around an axis that is closer to the center, and thusly minimize the collision with the rest of the body.

[@evgenysavelev837]

Or another idea, make the rotate with a little piece of the body, An elliptic halo of sorts

[@3000XJz]

Another episode to one of my favorite builds, it's nice

[@matshansson2020]

Wow, you two are incredibly talented. I wish I could build something like this. In any case, it is very fun and inspiring to follow your projects.

[@flyingtoothpick712]

I love the jig mechanism you made and cant wait to see the future final mechanism you'll make. it tickles my mech engineer student brain.

[@melderosa656]

Why not use Porsche 928 or 968 lights

[@Bramzel]

That was my thought as well but they didn't come with projectors as far as I could find.

[@H1WEX]

I agree, plus the projector lights are totally wrong for a 60’s car.

[@MuShinnen]

​@@H1WEXIt isn't a 60's car. It's a 60's INSPIRED car. There's no reason they shouldn't use better lights when they exist, and are easily accessible.

[@CrucibleCoachworks]

We didn’t use 968 or 928 headlights because the face of them is vertical when the headlights are up. And yes ‘60s inspired

[@melderosa656]

@@CrucibleCoachworks do you mean like the most beautiful car ever, the 60’s Lamborghini Muira. And you can solve you beam problems by having them go up to the correct angle

[@suecobandito8954]

Right, use a T handle and throttle cables to make a manual headlight extension. Also you can utilize Radio Control Servos which can “throw” open and close the headlight with a 12 volt interface, a switch or button on the dash. Maybe use the old corvette vacuum reservoir and spring method. Anyway you’re on the right track. Ryan with the bracket W. Make them pop down.

[@bonovoxel7527]

LOL you could skip the explanation the problem was already clear when the light fell into its hole like, "goodbye!" 🤣🤣🤣

[@albertofavalelli6361]

James Pumphrey would love to see this!!

[@k.s5079]

Watching project jigsaw is like nice little journey for me keep it up ❤😂

[@FACEBOOKS-WBDS]

I would have frenched the lens flush and split the housing and tilted the rest of the light to be level inside the body or even better just french the lower part of the light to where the top of the light was flush with the body. All of these options were being done in the 50's

[@rustywest9969]

You guys should’ve had the headlights tilt down into the body instead of popping up, that would’ve kept the top of the light in the same spot, and would’ve required less modification to the housing

[@sugoi4983]

probably easiest & cheapest to just go with miata pop up motors, you can rip the whole light bucket out at a junk yard relatively easy and you'll see how simple it is. You can pop of the oem linkage from bucket to motor using a screwdriver and replace it with threaded rod & heim joints for height adjustability. You'll need springs to keep tension on the headlights when they are up unless you got a newer idea, otherwise while driving the lights will vibrate and look bad.

[@gacattack1234]

You should probably make it into a sealed bucket with a drain hole at the lowest point connected to a pipe leading out of the frunk, but I guess you probably thought of that.

[@SiqueScarface]

With the headlights, the look of Project Jigsaw turns from sophisticated toy into serious sports car. Now it looks back to you (shameless "Spinal Tap" plug).

[@ztaphy]

It so cool to be able to follow your amazing build! Thank you! Keep it up!

[@964cuplove]

Gradually your reaching the Mirra solution… hence the above and below dishing on a Miura

[@paulnorris7270]

Very cool, there's a chance it might even work too!

[@jamest5149]

Its going to be interesting if theres enough adjustment in the headlamps to allow for the squint as both headlamps appear to be point outwards.

[@gafrers]

Always nice work

[@garvitchaudhary1]

Just make a metal channel which follows the path you need for the light to go. Then use a three point rocker attached to small dampers. You operate the rocker with a Motor or a hydraulic system.

[@trunk8d]

this is great work here. nice.

[@patlucas8227]

you could have gone with mk1 GT40 style headlights..they would sit well on that front end,they're still in keeping with the time period and way less fabrication hassle...

[@smudgetherealmc]

What about an articulation hinge (like on some hoods / boots) where the movement is not just a simple rotation?

[@MustafaKhan-hz5mr]

pop up up and down headlights pop up up and down headlights

[@theheadone]

Damn Donut, lol. I was having their jingle play in my head the whole video, haha.

[@greenkouki]

Could the headlight opening be flanged with simple tools without having to cut in and weld a bezel later? you could probably tip the edge with some modified vice grips very easily. Only need mayhbe 3/16 of a flange on that I bet. Curious to see how they pan out!

[@doubtannihilator2895]

Let's cut this lights and later we can think of a better way to do it!!!😂😂😂😂

[@PeterTremonti]

When you held up the guts for the headlight, I had a realization. I always wondered why beetles and no other VWs have replaceable lenses. It's because they're the same guts as a porsche and porches are cooler. Same parts though. Looks for a VW emblem on there somewhere.

[@arjr422]

It now looks like a gold fish!! Bwahahahahaa!! I loved it before the headlights. I still think it's cool....but Ican't UNSEE the "gold fish" face now!!

[@johnlist9054]

I'm not even done with the video yet, but I think that light placement looks awesome!

[@dcallan812]

Great update 2x👍

[@michel360]

You will need a 4-bar linkage!

[@bonovoxel7527]

She's got eyes now! :)

[@alman6581]

I have done a whole new assembly for a lens in a 96 chassis before. The thinking takes time. The doing isn't that hard.

[@martinjensen257]

How about looking at how they solve it on the LMP1 and LMP2 cars. Know that these are not popup headlights

[@Pallium_Industries]

What about pop-down headlights? Same movement, but hinged at the top because it would keep the vibe you're going for, allow for clearance, but also be unique.

[@justusmead]

I love robot Ryan

[@rydazim]

Why not get the Morimoto light and retro fit it? It’s a much slimmer design than the factory headlight.

[@theheadone]

I would highly recommend replacing that usb thumb drive with a reputable brand. spend the $10 now to avoid a lot of potential time lost in the future. Also, get a mouse for CAD! lol.

[@bonovoxel7527]

Apart of CAD with the touchpad which is mildly disturbing 😅 PLA+ is just for prototyping, right? I hope you go with ASA or Nylon on the final part, or it will melt ofc.

[@noforkGTS]

All this headlight work, and nobody said 928 or 968 the whole time! 😆

[@Biodebatable]

They answered this on another comment but basically they wouldn't be flush or complimentary to the body.

[@livefree2041]

I said a weeks ago..928 head lights would look sweet on the car..

[@johnlist9054]

When you guys have a contest to give away this car, I would like to put my name in for it. 😀

[@stacyevans1360]

I understand you are this far along but what about a mechanism that when the lens pops up then the lamp rotates toward the desired position. so basically when stowed the lamp is pointing even more vertical. The lens is hinged and the lamp is hinged.

[@0Heeroyuy01]

for that small amount of "pop up" i wouldnt have bothered with pop ups, would have just set the headlights behind a clear cover and angled them to shoot straight out

[@lennym1636]

In the beginning of the video I was going to say instead of popping the top of the light up just drop the bottom of the light BUT you more less got there. Or just do like the Opel GT car did...

[@Vaseliini]

I hope that I had a roof rack or something to put my long stack of tubing😅

[@Wahlsinn.1]

The design of the pop-up headlights is heavier, for one thing. On the other hand, it increases air resistance, which slows the car down. And Caroll Shelby also complained about something else. Namely, that pedestrians can be unnecessarily injured in the event of a collision. This enabled him to convince the US government in 1996 that headlights integrated into the shape of the Dodge Viper were much better in terms of aerodynamics. And the Viper was able to win the race on the Nürburgring. The moral of the story: pop-up headlights are quite simply the stupidest design there is.

[@CrucibleCoachworks]

Modern automotive infotainment systems are heavier and much more dangerous to pedestrians than pop up headlights. Some design decisions are based on personal preferences and pop up headlights are featured on some of the coolest cars in the world. Regardless, we think they are rad. 😎

[@Wahlsinn.1]

@@CrucibleCoachworks Yes, some people think so. But the pop-up headlights were not a free decision. They are based on the ban in the USA from 1967, when headlights integrated into the shape were banned. And from 1996 onwards, this ban was reversed. Into the oposit. And from then on, all the coolest cars immediately switched to aerodynamically integrated headlights. Whether it was a Viper, a Corvette, a Ford GT 2005 or an Aston Martin. It is the lighter design and the most aerodynamic. So it is really better for sports cars.🙂

[@benjamincrawford1444]

Halfway to 100!!

[@mcgill6546]

I would have thought you were going to try 928 headlights...

[@baahbb]

11:00 yall. What song is this? Where can i find more?

[@964cuplove]

No matter where you put the center, once the front lens is at the correct angle, the rear will also be at that angle…

[@maxmachac9756]

Oh its so derpy, and a little dopey

[@dmark2639]

Why not design a two stage pop up mechanism that comes straight up, then tilts forward? Then you wouldn't have to do so much modification and it would be cool and unique at the same time...

[@gavinhicks7621]

If you guys are cutting out an area for the bottom part of the headlights, why not just solid mount the headlight and leave the headlights inset?

[@blakehalfacre33]

Wouldn't a 928 HL assembly give you everything you're trying to achieve? You could put an elipsoid lens or whatever...

[@CrucibleCoachworks]

The face of 928 headlights are vertical when they are up. We want the headlights to look better than that. The Miura did it better

[@dimvanleeuwen8201]

make them pop-down like that restomod diablo

[@robertlarsen20]

Hey. maybe pop down lights would have been cool? just a thought :)

[@ssaxmanful]

I really dislike this style of lights. The whole point of popups is to not see the lights when they are down. I’ve always thought 928 look so incredibly awkward and it’s all because of the lights. Additionally the issue I’m seeing is the 993 bulb is so bulbous and raised compared to the body. I wish it were sleeker. I’ll trust the process but as of right now the lights make it look cross eyed and awkward instead of sleek sharp eyes. If it was me I would have shaped plexiglass or glass covers over top of lenses underneath like what the gt40 has

[@Exige333]

You simply should have bought some flat (!) round aftermarket LED lights for the NA Miata. Obviosly this doesn't work with this bulky Poesche lights 😂

[@alecjones7299]

METAL

[@eugemorin7786]

Do you have an inspection for your car to be street legal? Pop up headlights disappeared for a good reason. AMAZING WORK

[@pantster9855]

Did pop up headlights not get banned? In the U.K/Europe they were banned What happens at your annual inspection? This would still be assessed as a 200? Boxster. Pop up headlights were banned then, so the car would pass

[@mkpringle318]

Put lights up side down.

[@janblanckenberg883]

Multi point link like a rear trunk for the headlights?

[@drewlayda7358]

Why not just use 928 headlight mechanisms? Seems easier, but, maybe not.

[@big_red_joe]

21:57 Oh LoOk A sTrAwBeRrY

[@fd4639]

I understand that pop ups were banned many years ago, so are they legal once again?

[@marvsbazaar]

You cant rotate the headlight housing 180 degrees so the bulk of it is at the bottom?

[@wugely]

Imo the car might look better with sharp or rectangle lights and cutouts. The round shape is too soft in the presence of these sharp corners.

[@JoshsWorld]

I have the same blue Accord. Is yours the 1.5 or 2.0?