Any good places to get custom headlight covers made?

[Hiryu]

I'm looking to get replacements for my old headlight covers, but I'm not having luck finding places that can do so (anywhere in the world--I'm from the States). I've gotten my old ones scanned and have 3D files that can be used:





The old ones are flexible, but if the new ones are glass, I'm fine with that...I think one of the big issues is that they're curved:




Any suggestions are much appreciated-

Thanks!

[RedAndy]

they dont look too curved, surely a flat piece of anti-scratch polycarbonate sheet (Marguard or somethign similar) would make that easily enough? its simple stuff to work with, use a jigsaw and smooth the edge for a professional look, a bit of edge tape to black it up, and screw it in place.

also they look quite good in the pic - can't it be polished up? do you really need a new one?

[tribbles]

On my first kit car, I used some sheet metal, bend it into shape, put some perspex over it and stuck it in the oven for a few minutes.

Came out a treat!

[egomeister]

Look for someone who can drape form polycarbonate - shouldn't be too difficult to find someone in the USA to do that. Do you need any kind of certification?

[Hiryu]

Thanks for all the info guys-

I was able to search for the specific terms you guys dropped (drape form polycarbonate, Marguard, etc.) and was able to actually find a nearby place that sounds like it should hopefully be able to create a few batches of covers (I've actually driven by it several times without knowing it).

If that doesn't work, then I'll grab the Perspex and warm up the oven.

As far as the covers not looking too bad, that picture was taken earlier in her life (in fact, she happen to win the best in show award right after that was taken). They've aged, gotten a little scuffed, and even cracked since then (ironically, a lot of the wear came from the 3D scanning process that was done in order to get them replaced):



Thanks again

[egomeister]

I'm not sure what you'll do for the small lens region though... is that a self adhesive add-on?

[RedAndy]

perspex is too brittle and will shatter when the flies hit it!

use "lexan" or other brand of polycarbonate (Marguard is their brand with anti-scratch coating - a must for that use).

[Hiryu]

The round area with lines was actually carved into the covers...but I'm not worried about reproducing that.

I checked out the local place I found, but they only do large-scale orders (for Boeing, GE, etc.). However, they did point me to a company that does smaller orders, so I'm following up with them next week when they're open.

Otherwise (or maybe even regardless) I might get some Lexan/Marguard sheets and see what I can do myself--It looks like this probably has what I want (though this is not specifically for auto applications, as long as I can cut it and get a slight bend out of it...):
http://www.usplastic.com/catalog/item.aspx?itemid=...

[Steve_D]

That's quite a gentle curve so you should be able to make them yourself.
Have either a male or female tool CNC machined from your 3D model and make them in your oven.
When you make the tool extend the surface beyond your finished size. If you don't the plastic will droop over the edge of the tool causing a bulge at the edge.

Steve

[SDB660]

"lot of the wear came from the 3D scanning process that was done in order to get them replaced" What scanning process was used?!

[Hiryu]

The scanning process was either a white/blue light or laser scan, so it shouldn't have required too much contact with the covers. That said, I noticed some strange scarring and even some buildup of material at certain places, so I don't know if they needed to do something to stabilize the covers or even repair them?

[RedAndy]

i think they dropped them on a hotplate or something?!

how are you getting on with replacements?

[Hiryu]

So far, so good. I talked with the place I was referred to and they say they should be able to make them. I'm still following up on details, but this has been the most promising lead so far...

[mikeveal]

I'd make a fibreglass buck of the outside (with the part on the car), then heat mould the polycarbonate onto it. Knocking up a makeshift vacuum former should be a fun and easy project.
If not, try looking for a local vacuum former.

Most of the cost here is in making a buck, taking one off the car will make the job much cheaper.

Hmmn, you may need to use an epoxy based resin, the styrenes in the normal stuff may react with the polycarbonate.