Fibreglass headlamp covers?

Post by **Stuart** » Fri Jul 25, 2008 11:58 pm

My OE headlamps and associated gubbins weigh a damned tonne and have to be sent to the bin asap following my ethos of 'if it adds nothing other than weight, get rid' and that brought me to an old favourite on the old Dagenham. FRP headlamp shells.

Daft as this may seem, I cannot remember how we did this on the Sierra all of those years ago :lol: I mean, I know in principle what procedure I should follow but what sort of materials should I buy? Is it just the regular fibreglass matting and gel? Is one type more durable than another?

Any experts care to chip in?

Bladerider · Post by **Bladerider** » Sat Jul 26, 2008 12:19 am

Duh !!!

The man you needed to ask was in yesterday !!!

Im not helping am I dad ??

If you want that smooth racing look just model it on your head !! Chortle !!

Tub xxx

Post by **Stuart** » Sat Jul 26, 2008 1:13 am

Boom, boom Basil.

Did you not read the part in my post where I qualified the opinion of 'experts' chipping in?

Tsk, tsk. Back to the office J :poke:

Ian200sx · Post by **Ian200sx** » Sun Jul 27, 2008 9:07 am

Not an expert just use to do some laminating in boats. Are you thinking of taking a mould of the original glass for the shape? I

woody · Post by **woody** » Sun Jul 27, 2008 11:06 am

Great link Ian 8)

Stu I would buy the 5kg resin pack here... http://www.cfsnet.co.uk/acatalog/CFS_Ca ... 2.html#a18 and the 2kg of 300g chop strand mat here ... http://www.cfsnet.co.uk/acatalog/300gm_CSM.html

I wouldnt bother making a mould of the lights for a one off as it would just be time consuming I would...

Clean the lenses of the lights well
now the safe option would be cover the lense in pvc tape or sticky back plastic to guarantee you can release it ,or you can just build up some release. You can use spray lube or wax polish for this but build up some layers If you dont use the first option make sure you at least tape over gap where the lense joins the unit. Dont forget to prep the the tabs to mount the either.

I would lay 6-8 layers of cloth plus some extra bits on the tabs and leave to cure. try and make sure the excess doesnt fold over the light unit making it stuck to it.

Whilst its still on the light I would use an electric sander to fair it smooth, maybe some filler in the worst spots remember this will be the side you will see on the car.
Cut the excess cloth back to the light with a stanley knife, some sanding maybe require to make neat then pop it off ta da!

Post by **Stuart** » Sun Jul 27, 2008 5:38 pm

Great advice Ian and Woody :notworthy:

Will have a crack at that in due course and let you know how I get on

woody · Post by **woody** » Mon Jul 28, 2008 3:40 pm

No probs mate