...

• Found out that integrating headlights is top secret and trade secret so no info on that

• Keep headlight up through attachment to aerobody itself

  • idea for bolting to chassis was put aside as chassis is too far away from aerobody especially at the back

• Headlight need to be flush with aerobody to maintain aerodynamics

• Some ideas we came up with in meeting:

  • Tacky tape around headlight to keep it in place and stop air to pocket or flow, less drag that way

  • Regular tape was used in MS14 to keep it up

• This ideas kind of got put aside for re-consideration as the light can heat up to very high temperatures (80 degrees) so the tape melting or deforming is highly possible making tape of any sort unfeasible

• More ideas are welcomed!!!!!!!!

Possible Ideas to Keep Headlights Sealed and Flush w/ Aerobody

Types of Headlight Sealants - for sealing the car lights (actual light structure); for preventing dim/foggy headlights [1]

• Polyurethane Sealant

  • Pros: air-tight seal, effective in preventing water and dirt from entering

  • Cons: can be expensive (depends ono brand), difficult to remove

• Silicone Sealant

  • Pros: flexible, does not crakc/peel, inexpensive

  • Cons: --

• Heat Resistant Headlight Sealant

  • Pros: good if the car gets very hot (or from the engine heat or the light bulb)
    -- won't crack or melt under high temp
    ^will probably be our best option based on the MS14 light temperatures (unless we find a way to maintain a lower temperature)

We can try to use multi-purpose silicone or gasket sealant to keep a flush seal with the aerobody:

• Multi-Purpose Silicone

  • Similar idea to how silicone is used to seal bathtubs in a washroom

  • Silicone Rubber Auto/Marine Sealant [3]

    • This type of silicone is used for automotive parts water/weatherproof

    • This product specifically is used for keeping a seal between lights and car body

      • Can assist with keeping an air-tight seal

• For Permatex Red High Temp Adhesive Sealant (gasket sealant) [2]

  • Withstand temps between -54 amd 343 degrees celsius

  • Waterproof, and resists cracking/shrinking/migration

  • Meant for other car parts, but it might serve the purpose of creating a seal (cheap to purchase)

Resealing Custom Headlights: https://www.youtube.com/watch?v=ojcbi1IX_gw

[1] https://mycarmakesnoise.com/headlights/headlight-sealant-explored/#:
~:text=Polyurethane%20is%20a%20plastic%20material,from%20getting%20into%20your%20headlights.
[2] https://www.canadiantire.ca/en/pdp/permatex-red-high-temperature-rtv-gasket-maker-0383784p.html#:~:text=Temperature%20range%20%2D65%C2%BAF%20to%20650%C2%BAF,resists%20auto%20and%20shop%20fluids.
[3] https://www.dap.com/products-projects/product-categories/caulks-sealants/silicone/auto-marine-sealant/

Manufacturing

• Thermoforming of windshield is difficult (thinking of getting a company to do it for us for free just need to provide MDF and Mold)

• Jig will be 3D printed

• Thermoforming of headlight will be done in house just make sure to keep size small enough for it to fit in our machine

• Mold will be done with wood for head/tail light I believe (correct me if I’m wrong)

• Polycarbonate is used for windshield for REGS purposes