944_ono

Hey guys. So after some frustration, I finally got the lenses made and curved. Came out really well once I was patient. I used aluminum foil to cover my original light covers in the oven. Worked really well as long as you don't get any creases. Pictures will follow soon.

On a second note, can I use a propane torch to make some little adjustment to the curvature of the lense? Or would that fail epicly? Lol I know that kind of direct heat mght not be a good idea but I have a few little oopses on one lense that I want to fix. Itried throwing it back in the oven but when I heat the whole thing up I just couldn't get one bump out without creating another one.

mike10562004

use caution with the torch it will turn the lexan white, i say this from experience

piperporsche180944

I will be building a few prototypes revising the mounting design as well as well as the light beam. I have the oven, CNC, the whole deal. My hopes are high for the product. I can get the housing precision machined with the laser. If I can get a nice final product these may become available at a competitive price. I felt very discouraged when I saw the prices of these units online, $500 is to much, now I get to find out if that price is justified.

GC8

Better to use acrylic (Perspex) for this, because polycarbonate (Lexan / Makrolon etc) is hygroscopic and needs careful oven drying before forming.

944_ono

thanks, i am using acrylic btw. I just assume i should hold it far away and use patience. Lol we shall see how that goes

sdstimson

Finally finished, I'm still going to match the lenses to the car but for now these will do. Cost a little under $100 to make these including the $60 on the ballast boxes for the xenon lights

GC8

How are you lenses mounted/secured? I made my own lenses a few years ago but I havent been able to achieve an OEM looking mounting solution (and Im yet to find a picture of original GTS lenses revealing their secret).

Simon

Lead Foot 944

There is no Secret to it....The Covers were screwed using 3 screws to the buckets and a gasket inbetween the 2....Thats it...Seen it in person....

Buckaroo Banzi

[QUOTE=sdstimson;7543436]Finally finished, I'm still going to match the lenses to the car but for now these will do. Cost a little under $100 to make these including the $60 on the ballast boxes for the xenon lights

I like them...they are the best looking buckets I have seen...
They also are the cheapest but they don't look it..

Did I miss what kind of lights these are? They street legal in CA.?....do they perform better than stock?


Can you post some pics from the inside?

Are you planning on taking orders? can I put in an order for a set now?

thanks,

-BB

alxdgr8

Modified D9 lights....lenses are siliconed to the buckets around the edge.

Will get better pics when the car is done and out of the garage....right now there's only about 2.5ft of space in front of the car so I can't get a good angle.

mike10562004

nice!! this thread is starting to take off

Cass944

damn someone stole my idea

flosho

What thickness acrylic are you guys using.. 1/8 inch?

mike10562004

varies 1/8 will work and with the 1/4 inch you have to compensate with the height of your bucket so it sets flush

flosho

Ok guys, just attempted this, and may have left it in just a tad to long?

The way i did it was cover the head light cover in aluminum foil and place the sheet over the cover and let it droop. The acrylic started to show small bubbles.

I think I was close but cooked it a bit too long.. will have to try again lol. BTW I heated the oven to ~275 but then switched to broil.

I'm also thinking the foil started to sweat and caused the bubbles.