Fabbing Tail Light Lens

[BBPanel]

Is there any way to do this? I've seen some done before but I have no idea how it was done. Specifically, I'd like to make a one-piece lens for my 66 Nova. Here is an example - the only one I know of and I was told it is a one-off custom (NovaStar2). Or an alternative would be to replace the backup lens with a red one.

https://static1.pt-content.com/images/pt/2008/12/novastar2-1.jpg

[WS6]

I'm curious about this too and just plastic molding in general. I've got a really cool idea for tail lights for my TA but I must be able to mold/cast plastic or cut and polish it from a stock form possibly, say round stock.

[Mathius]

I think you want to do a yahoo search for vacuum forming. Also, as far as plastics go, there's a product called alumilite that you can use for the plastic resin for taillights.

Mathius

[68fusion]

streetrodder mag did a story from start to finish with a 55 or 57 a year or so back...a little too time consuming for me but would be neat to try

[derekf]

The show "Classic Car Restoration" on the DIY network used a mold and some sort of resin to make a new Packard taillight. I can't get to their site right now to see if they're going to rerun the ep or give any details, but might be worth looking into.

[Bigblue73]

Is there any way to do this? I've seen some done before but I have no idea how it was done. Specifically, I'd like to make a one-piece lens for my 66 Nova. Here is an example - the only one I know of and I was told it is a one-off custom (NovaStar2). Or an alternative would be to replace the backup lens with a red one.

https://static1.pt-content.com/images/pt/2008/12/novastar2-1.jpg

First off - I dig the exhaust on that car.

Have you ever thought of using a just flat sheet stock and using a diffusing film on the inside to disperse the light. The film is like a frosted mylar that is used on gas pump displays and other large displays to spread the light evenly and minimize the "Hot Spots" with bulbs, LED's.... One note, I have no clue if this is legal for the street or not.

[WS6]

here's what mathius was talking about and I'm betting derek you're referring to this as well, right?

http://www.alumilite.com/Applications/AutoRestoration.cfm

main page http://www.alumilite.com/index.cfm

definitely looks like a solution for what I'm wanting to do but I need to look into it more.

Derek, do you remember where they got the resin for the tail light and if it was something simple to work with? Was it clear or red? I really need to look into this some more. I'm in no hurry though, it'll be a few years yet before I can even begin work on my car. I just have something stuck in my head I want to make work or at least try.

[BBPanel]

Lots of good ideas - thanks for the replies. Making a mold for something that doesn't exist is going to be a little harder to do because of the creativity needed to make the mold. I might consider making a red lens from the backup lens I have now - not exactly what I wanted to do but perhaps a viable option.

[derekf]

Yeah, that's the stuff. The page with the details is at http://www.diynetwork.com/diy/ab_auto_restoration/article/0,,DIY_13680_3494404,00.html

[Mr.VENGEANCE]

^ damn.. thats one of the best/useful DIYs ive ever seen..

oooooh the possibilities!

[BBPanel]

Yeah, that's the stuff. The page with the details is at http://www.diynetwork.com/diy/ab_auto_restoration/article/0,,DIY_13680_3494404,00.html
All of the photo links are broken?

Hmm, strange - now they are viewable!

[jackfrost]

yeah, mold-making is what you're looking for, I think. unless you can just use flat sheet stock. I would create a part out of modeling clay or sculpting foam, and then create the mold from that.

this place has urethane mold making supplies:
http://www.uscomposites.com

[Mathius]

yeah, mold-making is what you're looking for, I think. unless you can just use flat sheet stock. I would create a part out of modeling clay or sculpting foam, and then create the mold from that.

this place has urethane mold making supplies:
http://www.uscomposites.com

Wood works too, so long as your grain doesn't leave a texture. Of course bondo and sanding fixes that as well.

Making the lense shape is the easy part. I've always wondered how well they actually would work, and LOOK without the textured shape that factory lights always use. I have never quite been sure if that's to direct the light, or just give the lense the illusion of being thicker than it is, to keep the light fixture inside from showing on the outside of the light.

Mathius

[WS6]

what I'm planning on doing would be molding an existing taillight that has some modifications to it. So for me, I don't need to worry about the texture as it's already there. My biggest thing was how do I pour the "plastic" which apparently is urethane and no big deal?

[xvette]

I made my tail light on my 55 conv. ,I made a male and female [ 1/8 differant ]molded them out of foam and bondo ,,then heated up the rubby red lexon 1/8 thick in the oven and press the two together , then trim them and made a back for them ,
here is a pic of the lights , they were hard because of the compound angles

http://pic4.picturetrail.com:80/VOL771/3006560/9419216/136608580.jpg

hope this link works , if not go to
www.picturetrail.com/55xvette (http://www.picturetrail.com/55xvette) and search 55 conv. album

[WS6]

love your car xvette. Saw it at YOE and was very pleased to hear you won. Do you still own it? Also, where did you get the ruby red lexan? Thanks

[xvette]

Thanks ,no sold the car to a guy in Ceder Bluff AL , the plastic, was from a shop in town .

[WS6]

hmm ok good. It was just in sheet form? I'll have to do some sourcing. I'm really interested in round or half round preferably but I can always mold that shape.

Do you have another car that will replace the 55?

[xvette]

yes it was in sheet form , and yes I am building another 55 2 dr post , ,c5 round tube ect ect

[WS6]

excellent! If your xvette is any indication, this next one will be fantastic as well. Will you make a post in the projects section or do you need to keep it low profile for Riddler maybe?

[Mathius]

Came across these guys tonight while perusing my chopper site: http://www.usplastic.com/catalog/category.asp?catalog_name=USPlastic&Category_Name=62&Page=1&clickid=topnav&cookie_test=1

I have no idea how good their prices are by comparison, but they seem to be the type of place that would have anything you needed as far as plastic goes. They may even have stuff for casting, I dunno.

Mathius

[Mathius]

If you want to try Xvette's method, this is probably a good read: http://www.fiberglassforums.com/showthread.php?t=8008

Came across it strictly by accident.

Mathius

[WS6]

need a user name and password Mathius Thanks for finding it and posting it here

[Mathius]

need a user name and password Mathius Thanks for finding it and posting it here

Sorry bout that. Registration is free. Pretty much the same as this place.

Mathius

[WS6]

got it. I need to register there anyway. Thanks