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Auto Headlamp Beam Changer - Chrysler '60
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wizard
Posted 2012-05-13 1:57 PM (#320857)
Subject: Auto Headlamp Beam Changer - Chrysler '60



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Hi, the time has come to start up the thread about the installation of the Auto Headlamp Beam Changer in my '60 Saratoga.

Serge "Sermey" has been assisting me for troubleshooting the electronics
Jörgen "1960ny" has supplied all the necessary info about the position and mounting

Thanks friends, without you I would still be stuck.

The first picture shows the hole pattern in the "cap" over the AstraDome - the photocell shall be centered on the cap

The second picture shows the position of the control box (measures will follow later)

The third picture shows a typical control box (note the too long cables - this is not a '60 control box, at least not one for a Chrysler)

Edited by wizard 2012-05-13 2:08 PM




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wizard
Posted 2012-05-13 2:24 PM (#320862 - in reply to #320857)
Subject: Re: Auto Headlamp Beam Changer - Chrysler '60



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Here is the photocell mounted in my car on the "cap" of the AstraDome. The position is really good, as it "melts in" so one does not stare at i all the time.

The holes were drilled wit a Dremel machine equipped with an 90 degree angular head. The mounting holes were threded M4, while the cable passage diameter is 10mm.

The worst part of it is of course drilling in the RD Autoline dash padding - this was a nervous operation - also the cable was difficult to rout through the narrow passage between the two aluminum parts of the cap.

The most difficult part to find was the photocell support, hence I also post the measures - that way you can cut and adapt a support for another car.

Edited by wizard 2012-05-13 2:32 PM




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Bart_59_Dodge
Posted 2012-05-13 10:10 PM (#320920 - in reply to #320857)
Subject: Re: Auto Headlamp Beam Changer - Chrysler '60



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OK Sven, here is the part that throws me. I have that same beam changer, purchased off of ebay. When it arrived, it had with it (2) nylon standoffs that go between the hard dashboard and the beam changer base.

I was thinking that these short nylon spacers were about the same thickness of the dashpad, so the pad doesn't deform as the beamchanger base is fastened tight.

I don't know if this is correct or not, maybe some of the other guys can chime in here.

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imopar380
Posted 2012-05-14 12:21 AM (#320932 - in reply to #320857)
Subject: Re: Auto Headlamp Beam Changer - Chrysler '60



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Sven, when you finish installing all these factory options you may just well have the most "Loaded" 1960 Saratoga in existence! Nice job, wish it was mine!
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61forfun
Posted 2012-05-14 2:12 AM (#320938 - in reply to #320932)
Subject: Re: Auto Headlamp Beam Changer - Chrysler '60



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Sven, I always appreciate your posts. They are very educational and your work is always so thorough. That Hiway Hi-Fi job was something else.

Edited by 61forfun 2012-05-14 2:13 AM
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wizard
Posted 2012-05-14 2:51 PM (#321005 - in reply to #320857)
Subject: Re: Auto Headlamp Beam Changer - Chrysler '60



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@ Bart - those distances might differs between the different cars. For the '60-'62 base, they are cast in the base. My guess here Bart is that the other cars, like Dodge, DeSoto and Plymouth could be delivered without the dash pad or with it, hence the bases where cast without the distances, hence fitted every car, only by adding the plastic spacers. As for Chrysler, they all came with the dash pad.
Does this makes sense?

@ Ian and Sam, thanks for your thumbs up - it is really fun chasing, investigating, repairing and learning about the options and gadgets. Then I really like to share this information for to save our friends from frustration and costly mistakes.

Edited by wizard 2012-05-14 2:54 PM
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imopar380
Posted 2012-05-14 3:56 PM (#321017 - in reply to #320857)
Subject: Re: Auto Headlamp Beam Changer - Chrysler '60



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On the 1960 Dodge, the Photocell was installed towards the center of the dash, on the metal part of the dash, behind the left side of the rear-view mirror. The dash pad on 1960 Dodges was only a partial pad that didn't extend over the instrument cluster area. I'll try to remember to snap a photo the next time I see my former Polara.

Edited by imopar380 2012-05-14 3:57 PM
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wizard
Posted 2012-06-01 3:31 AM (#323920 - in reply to #320857)
Subject: Re: Auto Headlamp Beam Changer - Chrysler '60



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Here's an update. For to be able to properly aim the beamer, one needs the C-3697 Scanner Leveling Hood. There are not many of those laying around, so I made my own one.
The first thing to do is to try to find the center line through the scanner body. I demounted the scanner tube from my spare scanner and made a shaft that fits snugly inside the body. A ring with the same diameter was produced in the lath. Now I could make proper measurements from the scanner tube center to the top of the body in both ends. Then I made the Leveling hood out of some scrap plastic that I had in the garage. The holes was cut with a hole saw and shaped to snug fit fit a Dremel grinding machine. In the front hole, I installed a stainless welding rod as a stop that will rest on the slant front of the scanner body. Now I have a flat surface where I can mount the level bubble.

Next step will be to mount the control box - now I don't have any excauses, so I must get myself together and do it.

Edited by wizard 2012-06-01 3:34 AM




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sermey
Posted 2012-06-01 5:43 AM (#323923 - in reply to #323920)
Subject: Re: Auto Headlamp Beam Changer - Chrysler '60


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wizard - 2012-06-01 9:31 AM  Now I have a flat surface where I can mount the level bubble.

This is 200% perfection (as Sven always does) for leveling! I know, the focus of the sensor in very narrow and thus critical when badly aligned, on horizontal as on side angle. But a naive question: What about when on road, the car is loaded, or the tires are weak? Means then the level of the car is being changed? I think next sneed would be an automatic leveling of the beamer to the street? Thinking further, I would insert my small Red Laser Pointer in the sensor housing and for adjustment beam to the coming car on the other side (:laugh: :laugh: )

 Anyway, this feature opens new dimensions when getting involved in, as nobody did before. Very interesting!  - SERGE - 



Edited by sermey 2012-06-01 5:50 AM
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wizard
Posted 2012-06-01 7:39 AM (#323928 - in reply to #320857)
Subject: Re: Auto Headlamp Beam Changer - Chrysler '60



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In fact Serge, the service bulletin points out that there shall be a full tank of gas (or equivalent weight added), correct tire pressure and the car should be rocked up and down and sideways for to settle the suspension in a normal position. No other load than the driver in the car. This means that the beamer should be aimed with the car in for that era "normal" load (one person). Yes, then fat mother in law and some extra pestering kids in the back would effect the performance (as well as get on the nerves of the driver )
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wizard
Posted 2012-06-01 10:51 AM (#323940 - in reply to #320857)
Subject: Re: Auto Headlamp Beam Changer - Chrysler '60



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Here is the home made C-3697 Scanner Leveling Hood - now with the level bubble.



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wizard
Posted 2012-06-08 11:22 AM (#324780 - in reply to #320857)
Subject: Re: Auto Headlamp Beam Changer - Chrysler '60



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Today I made the shafts with studs and threads. These are for to be able to mount the shafts really good on the cowl, with the studs and nuts. The length of the shafts is in my case 1" and they just clear the insulation padding. The shafts has a great metal to metal contact with the cowl and they shall provide a good ground for the beamer control box. At the same time, the Allen bolts, allows me to demount the control box very easily for good accessibility during service or troubleshooting. This was not a simple task and I have used all my cursing vocabulary and my body is aching - but, now that it is done I'm very pleased.

I will not inform about the measurments - you must check and confirm yourself - slight differences due to equipment. Anyway, this is very close to the OEM position.

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wizard
Posted 2012-06-11 5:50 PM (#325214 - in reply to #320857)
Subject: Re: Auto Headlamp Beam Changer - Chrysler '60



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First road test performed tonight! This option is really a cool one - it was really fun to leave the car in high beam and see the beamer dipping to low beam automatically. Still there are some fine tuning to do, the beamer is only aimed in level now and I did not made the sideway aiming yet. Still the aiming sideways was kind of ok when I checked it with a flashlight.



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Windsor Wendy
Posted 2012-06-12 5:37 AM (#325270 - in reply to #320857)
Subject: Re: Auto Headlamp Beam Changer - Chrysler '60


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Really enjoying this thread Sven! Always great to see your work and the high standards you commit yourself to...
What's the reason for the diodes in the connections? Or are those tiny resistors?
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wizard
Posted 2012-06-12 6:25 AM (#325271 - in reply to #320857)
Subject: Re: Auto Headlamp Beam Changer - Chrysler '60



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Aah - those are resistors and this modification comes from my friend Sermey here on the forum. This is still, let's say the beta version and still in testing state. I or Sermey will come back with an explanatión later on
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wizard
Posted 2012-06-17 1:49 PM (#325948 - in reply to #320857)
Subject: Re: Auto Headlamp Beam Changer - Chrysler '60



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The "Adaptive Resistor Network" was created by Serge "sermey" to match the photocell, as also the Transistor Circuit the network that replaced the old 12K tube, was important for the proper working.
The first step was to aim the beam changer photocell with my home made C-3697 Scanner Leveling Hood, which is used for the vertical adjustment. then the horizontal adjustment was done according to the manual and service bulletin, with a flashlight for to check that the photocell is aligned to the center of the car. NOTE - I adjusted mine just off center to the left for better reaction to the modern car lights.

Then followed "bench tests", for to set the sensibility for a good switching reaction. Also, a potentiometer was added to the adaptive resistor network, for to fine-tune and find the absolute best range for the photocell.

The bench tests are only for to get a starting point - the road tests means way much more and I adjusted it according to the modern situation - bear in mind that the original settings was done according the traffic and beamer on cars of the fifties. Today's street lights are very diffuse due to higher traffic, new illumination technologies such as halogen and LED lamps.

Now, finally it works as it should, under the condition: low traffic on country roads with not to many street-lamps and high reflective road signs. At today's higher traffic the automatic beamer acts sometimes irritated and switches unexpected.

The road to solve this was long, stressfull, interesting and a great challange that gave much understanding and satisfaction.

Again, a big thanks to Serge for his patience and helpfulness and Jorgen, always willing to share and help, without their kind help I would never solved this enigma.


Edited by wizard 2012-06-17 1:56 PM
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sermey
Posted 2012-06-18 2:01 AM (#326017 - in reply to #325271)
Subject: Re: Auto Headlamp Beam Changer - Chrysler '60


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wizard - 2012-06-12 12:25 PM  . . . sermey will come back with an explanatión later on . . .

The Adaptive Resistive Network (ARN) consists of resistors, no diodes, and is designed to fullfill multiple purposes:

1. Matching the high impedance photocell to the lower input impedance of the semiconductor circuit.

2. Shifting the higher threshold of the vacuum tube to the lower by the transistors.

3. Limiting the control range of the potentiometer on the photocell unit to be centered for best adjustment.

For an easy access, without disassembling anything, these resistors (6) are located floating outside on the connector, when a
fine-tuning is needed. The system has been checked only in test modus, not on the road. With an additional trimmer
the sensitivity then can be shifted up or down.

When all is working properly, these components could be inside the control box. There is no interference at all
when located outside. A simple and handy solution. Not so for dimensioning the correct values for proper operation
because of their interactive influence.

The tight cooperation with Sven was a pleasure to me to participate on this interesting and successful project. - SERGE -



Edited by sermey 2012-06-18 2:14 AM
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