I can see the shape coming in!

 

are you accounting for the area the lens cover is going to take? Or will this be more CWest (bubble) style?

-M

 

it'll be smooth, no bubble lens I believe...

 

Its coming together nicely. Cant wait for finished product!

 

evo is right.

i am taking the lens into account. when you look at the after carving picture you can see its smoothed out. what you may not be able to tell is that i carved it out to the same profile as the stock cover, i then carve the actual shape of the light. this insures the stock profile lens will fit.

the lens isnt flat. the stock cover isnt flat either. there are several benefits to this fact. the first is it will follow the stock lines , the second is this "bow" adds a lot strength (just how a dome or arch are the strongest shapes).

 

Im so excited.. id like to head up over there sometime this week if possible. pm me if i can superdan.. im free mostly in the after noon on wed and i will be heading home on fri. let me know!

 

We're taking totally different approaches (and I'll never sell anything), but I love that you're posting a step-by-step on here. It's definitely giving me motivation to work on my bi-xenon sleek lights
Keep up the great work

 

since the guy that was supposed to be helping me decided to repeatedly not show up or return my calls i went and talked to another teacher, and will be casting on tuesday.

 

bummer

 

the good news is hes far more reliable

 

wow, very nice. just caught up to this thread and you are doing some great work. cant wait to see how they turn out

 

james got a few pics when he stopped by, and is helping me with the wiring.

so when ever he gets a chance there'll be a few more teaser pics (i know how you love those evo, lol).

and james, it was great to meet you yesterday, but damn you for making me want a fd so so badly again (not that i lost my desire for one but it shoots through the roof again after riding in one).

 

i got the first and second coats of resin on the foam plug. once it is fully cured i will remove the plug and start fine shaping them. i will be able to get them identical a lot easier with them right next to each other. there wont be a whole lot of pics for a bit.

 

so when i was removing the passenger side plug from the car it tore in 3-4 pieces. fortunately they were all big pieces and go back together pretty well, so i should be able to piece it back together with no ill effects.

 

P.S. driver side came out fine.

 

Subscribed. I will likely be in for a set :-)

 

its sooooo nice when someone keeps the appointment they set. so i got the drivers side lens plug cast today. i may have to add a bit more of aluminum to this plug, we'll see. if it needs more i will add it on thursday, if not i will cast the passenger side on thursday. YAY, Progess.

 

thanks for the interest.

 

also i "glued" the shroud back together. i chose to use polyester resin, it seems to flow better and fill the cells, providing better adhesion. also i know there is some workability.

so that is curing now.

 

sorry for the late post of pics dan, but you are aware of the weekend i had and everything lol...
here are a few pics i took for the headlight before the resin.













hopefluly that should give everyone an idea of what they are looking like so far!

james

 

try getting a few more angles next time, LOL. jk, thanx for the pics.

 

wow, it looks really good! So, when is it done? LOL j/k =].

-AzEKnightz

 

joe's should be done in about a month.

 

looks great, can't wait to see the finished product!

 

the polyester resin worked really well gluing the shroud plug back together