Upgrading warning-light function & provision

[NASkeet]

Even by modest standards, the stock air-cooled engined VW, is poorly equipped with instrumentation; having only a fuel gauge (not all model years!) and speedometer, plus warning lights for low oil pressure, generator (i.e. dynamo or alternator) supply voltage, direction indicators (i.e. turn signals or blinkers), headlamp main beam and parking lights; which experience has shown to be wholly inadequate.

Most vehicle instrumentation systems, comprise gauges and warning lights; the former of which gives precise information about prevailing conditions, whilst the latter warns if these conditions deviate beyond acceptable limits.

According to ergonomics research, pertaining to the aeronatical, chemical process and nuclear industries, humans are better at making decisions, once warned of a situation, than they are at continuously monitoring gauge readings. Hence, gauges should be regarded as complementary to warning lights, not as substitutes. However, unless observed at the moment of illumination, conventional warning lights might go unnoticed, so ideally these should be linked to a single flashing warning light and/or buzzer, which are more likely to attract one's attention.

According to the following national, daily newspaper article, there are sadly, a significant proportion of both men and women drivers, who do not properly understand the meaning or importance of the common warning-light colours and symbols, dspite the fact that many have been Internationally standardised.

Ray Massey, "Dashboard Dunces", Daily Mail, Friday 3rd March 2006, page 35.

http://www.dailymail.co.uk/pages/live/femail/article.html?in_article_id=378822&in_page_id=1879

This is something which must be properly addressed by owners and drivers, before retro-fitting supplementary instrumentation.

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EIGHT-SEGMENT WARNING-LIGHT CLUSTER

When making provision for trailer towing or fitting electrical accessories, it is often desirable and sometimes obligatory, to fit a tell-tale warning light. To fit a large number of individual warning-light units, is often impractical, invariably untidy and might not be sited for optimum visiblity. In many cases, these deficiencies may be overcome by fitting a single warning-light cluster, such as that made by Lucas Industries Ltd., in Great Britain, which was original equipment for the Triumph Stag (a few exported to the USA), Triumph 1300, 1500, 2000 & 2500, Triumph Dolomite, Dolomite 1500HL & 1850HL and Dolomite Sprint.

The 60mm diameter Lucas warning-light cluster, of which there are at least two significant variants I personally possess, (illustrated in the following pictures), comprises eight equal segments, with interchangeable, plastic coloured filters; available in red, orange, yellow, dark-green, dark-blue and magenta. Rimmer Brothers Ltd., a Triumph spare parts supplier, in Lincolnshire, England, list several different part numbers, for Lucas 8-segment, warning-light clusters, but do not illustrate each of the variants.

Unlike the other coloured filters, which are made from translucent plastic, the orange filter, is made from transparent plastic. It is only found in the early model-year cars, whilst the magenta filter is exclusive to late model-year cars. I made my own orange, light-green and light-blue filters, from off-cuts of translucent coloured acrylic sheet (i.e. ICI Perspex®).

Although the external, circular, clear-plastic lens, features painted symbols representing specific warning-light functions, these can be readily removed if desired, using strong organic solvents, such as paint thinner. Custom designed symbols for the warning-light cluster, could be easily substituted for the originals, by printing them on a circular mask of thin, transparent sheet material, which would fit behind the external, circular, clear-plastic lens.

Home-made transparent mask orientations, for customising a Lucas, 60 mm diameter, 8-segment, warning-light cluster.

The types of material (some of which are compatible with photocopiers and computer laser printers) used for overhead projection transparencies, would be suitable for this purpose. Symbols could be printed onto the transparent sheet, either by hand printing with a fine-nibbed, permanent marker pen, photocopying a maper master copy, or laser printing directly from a computer-generated design.

Sometime ago, using Adobe Illustrator, on an Apple Macintosh computer, I produced the specimen, custom warning-function symbols, for the following:

Right-Hand Direction Indicators

Left-Hand Direction Indicators

Trailer Direction Indicators

Headlamp Main Beam

Headlamp Dipped Beam

Front Fog Lamps

Rear Fog Lamps

Auxiliary Reversing Lamps

Flood Light

Battery Charging

Oil Temperature

Coolant Temperature

If the colour filters must be made thinner, to accommodate the transparent mask, this may be done by rubbing against wet, fine-to-medium grit, silicon carbide (aka "wet & dry") abrasive paper, backed by a solid surface (e.g. on the bottom of a basin, partially filled with water). Incidently, I used this method, when making some substitute orange, yellow, light-green & light-blue, illuminated-switch lenses, for the VW Type 1, 3 & 4 heated rear-window switches, utilised in my 1973 VW Type 2, for auxiliary front driving lamps, front fog lamps, rear fog lamps and auxiliary reversing lamps.

Electrical connection is made via a multi-way, thermoset-plastic connector block, with captive, latched, female, push-on, copper connectors, which fit onto riveted brass pins, on the back of the warning-light cluster's printed circuit board. Although replacement push-on connectors, are probably unavailable, they are relatively easy to salvage and re-use; having myself successfully done this in 1983, when I retro-fitted such a warning-light cluster, to my 1974 Triumph Toledo. The warning-light cluster, is held in place within the dashboard instrument panel, by means of a large-diameter (i.e. >60mm) helical spring and retaining ring.

Having recently acquired a VDO Cockpit, 80mm diameter, accessory speedometer and 52mm diameter fuel gauge, I shall at sometime in the future, fabricate a comprehensive, instrument panel, to substitute into the existing steel dashboard, of my1973 VW Type2, incorporating these, together with several other gauges and two of the aforementioned, 8-segment warning-light clusters.

Fully-assembled, early & late-pattern, warning-light cluster units, with helical spring, retaining ring and multi-way connector blocks

Early pattern, warning-light cluster lens with separate right & left-hand direction-indicator warning lights

Late pattern, warning-light cluster lens, with single direction-indicator warning light and heated rear-window warning light.

Early-pattern (dark-brown PCB on left) and late-pattern (light-brown PCB on right) printed circuit boards with bulb holders & bulbs

Early-pattern (dark-brown PCB on left, with 8+3 rivetted brass connection pins) and late-pattern (light-brown PCB on right with 12 rivetted brass connection pins) showing the connection pins and associated push-on connector blocks.

Both early & late-pattern circuit boards, with bulbs, coloured filter segments and reclaimed, captive, latched female copper connectors.

The factory-stock, coloured plastic filter segments, for the early model warning-light cluster, are:

red, orange, yellow, green & blue.

The factory-stock, coloured plastic filter segments, for the late model warning-light cluster, are:

red, yellow, green, blue & magenta.

For my own purposes, I have made additional coloured filter segments, in the following colours:

orange, yellow, light-green & light-blue

If salvaging and customising second-hand warning-light clusters, is beyond one's scope, there are various accessory warning-light clusters available, of which the following are two examples, but one is likely to pay dearly for the privilege!

Shown on page 81, of the 1997 Europa Specialist Spares catalogue, is an SWF, 2-position, rectangular warning-light module, with what appears to be a choice of 31 different, coloured (red, orange, yellow, green, blue & white) warning-light lenses, with or without symbols. These warning-light modules, illuminated rocker switches and/or blanking plates, can in turn be mounted, into a 3 or 6-position, in-dash or under-dash, switch & warning-light panel.

http://www.europaspares.co.uk

Circa 1997 etc, SWF modular warning lights & lenses.

Circa 1997 etc, SWF modular warning lights & lenses.

Shown on page 22, of the 1992 VDO Automotive & Industrial Product Catalogue, is a VDO "Modular Cockpit", 8-position, rectangular warning-light module, with what appears to be a choice of 20 or more, different, coloured (red, orange, yellow, green & blue) warning-light lenses, with or without symbols.

Circa 1992 etc, VDO modular warning lights & lenses.

Circa 1992 etc, VDO modular warning-light lenses.

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WARNING-LIGHT OR BUZZER FUNCTIONS

Automotive warning lights or buzzers, serve either as a tell-tale to show that some system is operative or in use, or to warn that some measurable quantity has strayed beyond acceptable limits. Some tell-tale warning lights, are incorporated into illuminated dashboard switches, such as for hazard-warning lights and the factory-fitted heated rear window. Similar illuminated dashboard switches, can also be used for various accessory lights and systems.


Possible examples of the former, are:

Brake lights on - one of my own developments!

Side lights (aka parking lights)

Headlamp dipped beam (aka low beam) - one of my own developments!

Headlamp main beam (aka high beam)

Left-hand, flashing direction indicators (aka turn-signals or blinkers)

Right-hand, flashing direction indicators (aka turn-signals or blinkers)

Hazard-warning lights (aka emergency flashers)

Trailer's left or right-hand, flashing direction indicators (aka turn-signals or blinkers) - obligatory in some countries, including Great Britain

Auxiliary front driving lights

Roof-mounted, auxiliary front driving lights - for off-road use only!

Front fog lights

Rear fog lights (aka rearguard fog lamps)

Auxiliary reversing lights (aka back-up lights)

Roof-mounted work lights

Heated rear window (aka back light)

Heated front windscreen (aka windshield)

Hand brake (aka parking or emergency brake)

Campervan elevating roof (aka pop-top) raised


Possible examples of the latter, are:

Low generator (aka dynamo or alternator) voltage

Low and/or excessive engine-oil pressure

Low engine-oil level

Low and/or excessive engine temperature

Engine knock (aka spark knock, pinking, pinging or detonation) - crucial for Second & Third World touring!

Low and/or excessive transmission temperature

Dual-circuit, hydraulic brakes', single-circuit failure

Low brake hydraulic-fluid level

Low fuel level

Low and/or excessive tyre pressures

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INDEPENDENT DIRECTION-INDICATOR (i.e. TURN-SIGNAL or BLINKER) WARNING LIGHTS

The following link, gives details of the direction-indicator warning-light modification, for the 1968~79 VW Type 2 (and possibly the VW Types 3 & 4), so that the left-hand & right-hand warning lights flash independently of each other, in conjunction with the corresponding direction indicator lamps:

http://www.thesamba.com/vw/forum/viewtopic.php?p=2...15#2563015

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UNMASKING THE HEADLAMP MAIN-BEAM WARNING LIGHT

When driving your 1968~79 VW Type2, have you ever wondered why the headlamp main-beam warning light, barely glows when illuminated, whilst all the others are as clear as day? The reason for this, is an opaque mask with a 2·5mm (i.e. 1/10-inch) square hole, behind the blue lens. To improve matters, the mask may be removed completely or the hole enlarged using a hole-punch, cork-borer or small wood-chisel.

This procedure is fairly straight forward, but does require the instrument panel to be removed from the dashboard aperture; necessitating the removal or disconnection of the Phillips-head, self-tapping screws (aka sheet-metal screws), from each corner of the instrument panel; the red heater-control & blue ventilation control levers; and the speedometer drive cable.

If there is insufficient slack in the electrical wiring, some or all of it will need to be disconnected from the instruments, after first labelling which wires connect to what. My 1973 VW Type2, has a home-made, custom, modular wiring loom, which enables me to easily remove the instrument panel and even whole the dashboard; disconnecting the associated wiring-loom module, simply by unplugging a few two-piece, multi-way connector blocks (salvaged from the local car breakers' yards), with latched, captive male & female connectors!

Having removed the instrument panel from the aperture, the instrument module (i.e. fuel gauge, warning-light cluster & speedometer) may be removed from the black, plastic housing, after first unfastening five hex-head, self-tapping screws (one at the speedometer end and four along the straight sides), using a 6mmAF spanner, socket or nut driver.

Finally, remove the circular light-grey centre trim and dark-grey plate (at least, they are what exist on my early-1973 VW Type 2!), which hold the warning-light lenses in position, by unfastening the two small, slot-head screws. The loose-fitting warning-light lens may now be removed; discarding the opaque mask or enlarging its hole and replacing it as preferred. Reassembly and refitting of the instrument panel, is simply the reverse procedure.

I suspect that the headlamp main-beam warning lights of the VW Type3 (i.e. 15/1600 Saloon, Variant & Fastback) and VW Type4 (i.e. 411/412 Variant & Fastback), are also similarly masked.

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BRAKE-LIGHT-ON INDICATION

When slowing down, I commonly just ease off the accelerator pedal, using engine braking, rather than the hydraulic brakes. Unfortunately, this often takes tail-gating drivers unawares, so I wanted a means of activating the brake lights, without actually using the hydraulic brakes!

When driving my 1974 Triumph Toledo 1300, it was a simple matter to slightly depress the brake pedal and listen for the click of the brake-pedal-lever operated, brake-light switch, but this is not an option with the hydraulic-pressure operated brake-light switches, fitted to Volkswagens. Hence, I opted to connect a dashboard warning light, in parallel with the brake lights, to show when the brake lights illuminated.

A further refinement, was to connect a hand-operated, push-button momentary switch, in parallel with the hydraulic-pressure operated brake-light switches, so that I could illuminate the brake lights, without having to use the brake pedal.

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RETRO-FITTING AN HYDRAULIC BRAKE-CIRCUIT FAILURE WARNING LAMP

Refer to the following link, for Brake-system, electrical circuit modifications & upgrades, which includes the retro-fitment of an hydraulic-brake-circuit failure warning light facility, using either the late-model, 4-terminal (terminals labelled 15, 31, 61 & K) warning-light unit (VW part No. 113 919 233B) or the early-model press-to-test, 2-terminal (terminals labelled 15 & K) warning-light unit (VW part No. 111 919 233B), with separate, 1-terminal bulb holder (identical to the normal warning-light & instrument-illumination bulb holders).

http://www.thesamba.com/vw/forum/viewtopic.php?p=2570436#2570436

[Tram]

You had me until the "Lucas England" part. Could I interest you in a warm beer?
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Немає виправдання для війни! Я з Україною.

[NASkeet]

[zozo]

The problem is, the "errant" colonies HAVE heard about Lucas.

What ever happened to the "Great" part of Great Britain?

[NASkeet]

[racerx45]

This post reminds me of a bumper sticker I once saw on the back of a Triumph it read:

[Lind]

I would sooner shove burning coals up my arse than install something that looks like this onto any of my cars. and even if it did look cool, it is still made by lucas, "prince of darkness"

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Wanted:
Idaho VW license plate frames or other dealership items.
VWoA literature and early dealership or distributor literature/pictures/information
.

[zozo]

Buy lights from "the prince of darkness". Maybe that's why all things Lucas suck all things.

[NASkeet]

[zozo]

[NASkeet]

[NASkeet]

I am pleased to report, that at least one person in the USA, appreciates Lucas Industries, 60 mm diameter, 8-segment warning-light clusters, as fitted to various BLMC Triumph cars. Tom Cloud obtained some from Australia, in November 2007, via E-Bay, to customise his dune buggy.

[coad]

This is all I need. If it ever comes on you know you're in trouble.

[chrisradioman]

Good post Nigel
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http://www.vintagevwweddings.co.uk/contact.html

[NASkeet]

[Migit]

Indeed, that is a VERY interesting indicator! PLease grace us with more info on it! It would look great next to my 3 in 1. Were there any other variations?
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Looking for a 58 euro hardtop!

[NASkeet]

[coad]

[Lind]

[NASkeet]