Working on Another Version of Kev's Headlights

I need some !!!!

Have you thought about making a cast of the inside of the lens? That way, when the lexan is vacuumed, it would occupy the same space as the original plastic instead of being streached over the plastic.

I REALLY want to learn how first, then do this myself.

Can anyone post up a site where I can learn how to 1st how to build the mold I need and 2nd learn how to do this at all? Just want to learn.

Originally posted by vinnietbird:
I need some !!!!

Everyone that drives a fox at night needs some!

Originally posted by Huey866:
Have you thought about making a cast of the inside of the lens? That way, when the lexan is vacuumed, it would occupy the same space as the original plastic instead of being streached over the plastic.

A mold of the inside of the lense would not work for what I want to do. If you look at the OEM lense it has all of those lines on the inside of the lense. Those lines are used to distribute the light from the original housing, but I no longer want the light reflecting from the original housing. I want the light to come from the aftermarket projector that I am installing.

Making a female mold from the outside of the lense would work, but from what I have read that dealing with female molds is even more difficult.

Originally posted by Shane B:
I REALLY want to learn how first, then do this myself.

Can anyone post up a site where I can learn how to 1st how to build the mold I need and 2nd learn how to do this at all? Just want to learn.

Youtube is a great place to start. There is hundreds of different variations of this process, the table I am using is fairly different than what Kev used. Here is two forums that are often referred to, I tried to register at tk560 2 weeks ago but have not yet been approved....
http://www.cnczone.com/
http://www.tk560.com/phpBB2/index.php?si...352a95d4c1

There is a lot of trial and error with learning vacuum forming. Figure on wasting a lot of plastic! lol

I think I am going to remove the cooling tips and maybe all of the lettering, I am having my doubts as to how well they are going to show through.

I was just a thought. Regardless, If you get something your happy with, I want a set. :-)

Originally posted by Huey866:
I was just a thought. Regardless, If you get something your happy with, I want a set. :-)

Thanks! That was the reason I posted it on here so early, I want input from others! You never know when someone will think of something that will improve the process!

When it gets to where they turn out nice, I will be glad to make some for others.

http://i1224.photobucket.com/albums/ee36...038421.jpg

http://i1224.photobucket.com/albums/ee36...006600.jpg

Best one so far! Removed the cooling tips and the dot#'s but left the Ford logo. The logo is barely noticeable.

http://i1224.photobucket.com/albums/ee36...534513.jpg
http://i1224.photobucket.com/albums/ee36...533491.jpg
http://i1224.photobucket.com/albums/ee36...532404.jpg
http://i1224.photobucket.com/albums/ee36...532925.jpg
http://i1224.photobucket.com/albums/ee36...531881.jpg

Just a couple of photos on an old housing checking fitment.

Wow! Those edges look crisp! What did you cut them with? How much time did you leave the plastic in the oven and at what temp? Did you use document clips around a metal frame to hold the plastic or did you do something else? That looks really terrific, man. Excellent job. That housing is trash though! Gross! Are you gonna paint the housings black as a backdrop to your new lenses and headlight inserts or do you have another color in mind?

Originally posted by Kev:
Wow! Those edges look crisp! What did you cut them with?

Electric Dremel type tool with a cut off wheel, worked really well!

Originally posted by Kev:
How much time did you leave the plastic in the oven and at what temp?

hehe Literally close to an hour. I found what seems to work best is to preheat the oven to about 150 and let the plastic sit in there for like twenty minutes. Then move the temp up to 250 for about 10 mins, then move the temp up to 300-325 for 5-10 mins (basically until it had the proper amount of sag).

I had tried just going straight to 350 and even 400 but just wasn't getting the results I wanted. I happened to read an article about a guy that left his in the oven overnight at 100, I thought that was a bit extreme but who knows... I just shortened his process, the idea was that the inside of the plastic wasn't getting as warm as the outside.

Originally posted by Kev:
Did you use document clips around a metal frame to hold the plastic or did you do something else?

The metal frame and clips did not provide enough stability. When the plastic was heated the frame would become very flimsy which just made the whole process that much more difficult. I ended up taking some timber (about 1 1/2" wide and 1/2" thick) and making a healthier frame. I held it together by drilling a whole in each side and using 1/4" flush screws with wingnuts on the other side.

Originally posted by Kev:
That looks really terrific, man. Excellent job. That housing is trash though! Gross!

Thanks! Yea, I have gathered up a lot of housings most of them are in similar shape, I have two really nice sets, but they are in the cars and won't be part of these modifications!

Originally posted by Kev:
Are you gonna paint the housings black as a backdrop to your new lenses and headlight inserts or do you have another color in mind?

I'm still debating this. I am pretty sure I am going to be installing HID projectors. These in particular -> http://www.theretrofitsource.com/product...tuu6j97dne I am going to call them tomorrow and see if they have any further advice.

http://www.youtube.com/watch?v=mg_C_jtonZw
Then probably make a shroud similar to this, skip to 8:17 to see the actual shroud. I think that would turn out pretty sweet. If I go this route I'll just take some pictures and play with them in Photoshop before painting to see what color looks best.