new fog light lens [left side] needed,,,£220-£250 from usuals or $70 frm lyndsey

[jasonp]

Mine are cracked Jason. I put some lens repair tape on them then used the Promax perspex protectors. With the tape and the protector you would literally need to get your eye right to them to know they were cracked.

Rob,,thanks for that,,,,
i have clear coloured tape on at the moment and you wouldnt know the difference unless close up but it concerns me if i get water ingress but plus car is running so well with everything working great so kinda feels incomplete but even with the tape over covering,, its still a mot pass but i would like it sorted,,,,,jp

 

[zcacogp]

Topical thread Jason - thanks for posting. I've been thinking about these fog light covers and it can't be that difficult to use some existing ones to cast a mould and then cast some replacements. There are a number of YouTube videos doing much the same thing and it doesn't look too hard. Here's one:

https://www.youtube.com/watch?v=QMe9MOBjkmc

Obviously, the right time to do this would be while you have some decent lenses to make the cast from - and mine are patched up in much the same way that Rob speaks of.

Has anyone tried this sort of thing and, if so, what sort of results do you get? Is it worth it? Would anyone have any good existing lenses for me to make a mould from?


Oli.

 

[jasonp]

Hey Oli
A happy and healthy 2018 to you and mrs zz
just seen the promax covers which Paul mentioned and they look perfect
And screw in so those plus some very
Strong clear tape behind should do the trick if tipec chaps part don’t work out,,,,jp
post edited to say Promax covers not currently in stock,,,,,,jp

 

[Frenchy]

I have a couple of sets of covers if anyone is interested, one set flush mounting and a couple of sets that stand proud.
Pm if interested for price and details.

 

[jasonp]

I have a couple of sets of covers if anyone is interested, one set flush mounting and a couple of sets that stand proud.
Pm if interested for price and details.

PM sent Frenchy and thanks,,,jasonp

 

[wolfie308]

Topical thread Jason - thanks for posting. I've been thinking about these fog light covers and it can't be that difficult to use some existing ones to cast a mould and then cast some replacements. There are a number of YouTube videos doing much the same thing and it doesn't look too hard. Here's one:

https://www.youtube.com/watch?v=QMe9MOBjkmc

Obviously, the right time to do this would be while you have some decent lenses to make the cast from - and mine are patched up in much the same way that Rob speaks of.

Has anyone tried this sort of thing and, if so, what sort of results do you get? Is it worth it? Would anyone have any good existing lenses for me to make a mould from?


Oli.

Looks easy enough in the video doesn't it?.....but I can assure you it isn't. How do I know?......I've been making many different car lenses in clear, red, amber and smoke on an almost daily basis since 2005[]

I use a completely different method/material for the moulds, but cast in a similar polyurethane resin. To start, you will need a vacuum chamber to degas the resin. Mine is big enough to take a bucket as I degas the silicone to ensure no bubbles against the surface of the cast lens. To ensure an excellent result, it would be imperative to use new lenses IMO as any road rash on used parts would be replicated and worsen on successive casts.

I don't have a unit to hand to check......how is the glass bonded to the backing case? Have they used a heat softening mastic which would allow the two parts to be separated by oven heating? If someone has a damaged unit and could try it, I'd be interested how heavy the actual glass is to calculate the cost of the resin per lens. The resin is much dearer than you'd think....the stuff I use has just gone up dramatically to about £60/kg, but is the market leading product and best in my experience.

 

[blade7]

Looks easy enough in the video doesn't it?.....but I can assure you it isn't. How do I know?......I've been making many different car lenses in clear, red, amber and smoke on an almost daily basis since 2005[]

Could you make clear headlamp covers? I quite fancy the fixed projector type conversion, but I've read the quality of them can be iffy.

 

[zcacogp]

Looks easy enough in the video doesn't it?.....but I can assure you it isn't. How do I know?......I've been making many different car lenses in clear, red, amber and smoke on an almost daily basis since 2005[]

I use a completely different method/material for the moulds, but cast in a similar polyurethane resin. To start, you will need a vacuum chamber to degas the resin. Mine is big enough to take a bucket as I degas the silicone to ensure no bubbles against the surface of the cast lens. To ensure an excellent result, it would be imperative to use new lenses IMO as any road rash on used parts would be replicated and worsen on successive casts.

I don't have a unit to hand to check......how is the glass bonded to the backing case? Have they used a heat softening mastic which would allow the two parts to be separated by oven heating? If someone has a damaged unit and could try it, I'd be interested how heavy the actual glass is to calculate the cost of the resin per lens. The resin is much dearer than you'd think....the stuff I use has just gone up dramatically to about £60/kg, but is the market leading product and best in my experience.

First-hand experience! Fantastic - thanks for posting Richard. []

I've never done this sort of thing but have watched the videos and it's something I'd like to try, but (as you said) the kit is extensive and it would be quite expensive to buy all of it just to play around. A vacuum chamber is the obvious biggie but I wonder if you could make it work by putting a sheet of perspex across the top of the bucket and attaching the vacuum hose to the middle of the sheet? (What sort of vacuum do you need to pull to get the bubbles out?)

I take your point about needing to use new (and perfect) lenses but could you put tape over the front of the lenses before using them to make the mould? That would give you a smooth front. Or use some wax to fill any minor imperfections?

The glass isn't bonded to the backing case - they are screwed together. There would be no need to heat them to separate them.

I'd hazard a guess at the weight of the lens being around 50g. Presuming the casting resin has the same density as the glass of the original that would mean a resin cost of £3/casting (presuming no waste). Given the cost of new items this would make for a very big saving.

Out of curiosity, what other car lenses have you cast and why?


Oli.

 

[wolfie308]

Looks easy enough in the video doesn't it?.....but I can assure you it isn't. How do I know?......I've been making many different car lenses in clear, red, amber and smoke on an almost daily basis since 2005[]

Could you make clear headlamp covers? I quite fancy the fixed projector type conversion, but I've read the quality of them can be iffy.

You mean like the ones DeutschNine used to make?....not sure if they're still around, but I think they went bust.

You'd need to heat form acrylic sheet for this application which isn't what I do. Maybe suited to someone on Rennlist?

 

[944 man]

Has anyone pointed out that North American spec PU lamps are completely different? Same size, of course, but with different laps inside so their lenses will not suit our cars.

 

[blade7]

Could you make clear headlamp covers? I quite fancy the fixed projector type conversion, but I've read the quality of them can be iffy.

You mean like the ones DeutschNine used to make?....not sure if they're still around, but I think they went bust.

You'd need to heat form acrylic sheet for this application which isn't what I do. Maybe suited to someone on Rennlist?

[/quote]

That's what I was thinking of. D9 used to buy in most of the parts they sold.

 

[wolfie308]

Looks easy enough in the video doesn't it?.....but I can assure you it isn't. How do I know?......I've been making many different car lenses in clear, red, amber and smoke on an almost daily basis since 2005[]

I use a completely different method/material for the moulds, but cast in a similar polyurethane resin. To start, you will need a vacuum chamber to degas the resin. Mine is big enough to take a bucket as I degas the silicone to ensure no bubbles against the surface of the cast lens. To ensure an excellent result, it would be imperative to use new lenses IMO as any road rash on used parts would be replicated and worsen on successive casts.

I don't have a unit to hand to check......how is the glass bonded to the backing case? Have they used a heat softening mastic which would allow the two parts to be separated by oven heating? If someone has a damaged unit and could try it, I'd be interested how heavy the actual glass is to calculate the cost of the resin per lens. The resin is much dearer than you'd think....the stuff I use has just gone up dramatically to about £60/kg, but is the market leading product and best in my experience.

First-hand experience! Fantastic - thanks for posting Richard. []

I've never done this sort of thing but have watched the videos and it's something I'd like to try, but (as you said) the kit is extensive and it would be quite expensive to buy all of it just to play around. A vacuum chamber is the obvious biggie but I wonder if you could make it work by putting a sheet of perspex across the top of the bucket and attaching the vacuum hose to the middle of the sheet? (What sort of vacuum do you need to pull to get the bubbles out?)

I take your point about needing to use new (and perfect) lenses but could you put tape over the front of the lenses before using them to make the mould? That would give you a smooth front. Or use some wax to fill any minor imperfections?

The glass isn't bonded to the backing case - they are screwed together. There would be no need to heat them to separate them.

I'd hazard a guess at the weight of the lens being around 50g. Presuming the casting resin has the same density as the glass of the original that would mean a resin cost of £3/casting (presuming no waste). Given the cost of new items this would make for a very big saving.

Out of curiosity, what other car lenses have you cast and why?


Oli.

Hi Oli, yes the vacuum chamber is a biggie....mine is 43cm in diameter and about 50cm high. It is 'powered' by an industrial rotary vane pump and the complete kit cost me £1k back in 2005.

Given that the chamber wall is about 1/4" steel, you'll understand that a bucket and a Dyson won't do the job.

Some confusion.....the glass is attached/bonded to the plastic part that supports the reflectors/bulb holders. As you say, this is then screwed to the backing case.....the ones that always rust and have to be drilled out.

I think you're well out on your weight estimation of the glass.....although the resin would be lighter, I'd guess it would work out nearer 250 grms. Taping or filling the surface is a non starter. Don't forget the cost of the mould materials which would be circa £200 plus making custom size mould cases.

What other lenses and why will have to wait until after supper, but I started with clear rears for my first 944 which were particularly difficult as a first project since the amber pieces had to be cut out of and destroying a pair of excellent condition units.

 

[T911UK]

Has anyone pointed out that North American spec PU lamps are completely different? Same size, of course, but with different laps inside so their lenses will not suit our cars.

Yep, only one light unit in them, not 2

 

[jasonp]

Big thanks to Frenchy for saving the day,,,,,jasonp

 

[jasonp]

Huge congrats to Jim/Frenchy,,,
recieved the fog light covers this morning,,,,i would take some pics but just cant load them up,,
would be great if we had tapatalk like on our watch forum
Covers look that simple i may be able to fit them myself but that remains to be seen[8|],,,,
Along with a £18 roll of super adhesive transparent tape that should having it look almost perfect,,,,,,
many thanks again Jim,,,,,jasonp