Custom molded headlight lens

[Paul1965]

Well, I finally got the finale estimate for having a new lens molded. And while they would be only $45 each, setup and pattern costs completely blow the price out of proportion. At a total of $750 for having 6 lenses made I can't help but think they priced it so high so they could get out of doing such a little job. So it's back to making my own forming table and see what happens.

[fj11.5]

That's only slightly higher than the quote I got for having a bellypan and mould made,,, good  luck making your own, id still be interested if you make extras

Rod

[Paul1965]

That's only slightly higher than the quote I got for having a bellypan and mould made,,, good  luck making your own, id still be interested if you make extras

Rod

I really think it's a matter of them not understanding what I'm asking for. I exchanged a few more emails with them after getting the quote, and they're thinking they needed to vent the glass and do some other special setup work to make the mold. My donor headlight should be here Thursday, so I'm popping the lens off and heading back Friday to show them what it looks like outside the bike.

[fj11.5]

Fingers crossed once they see what your actually after the price will drop, I wouldn't of thought vents would be needed

[Paul1965]

The donor headlight arrived today and the lens has already been removed. I'll stop by the molder tomorrow afternoon and see what they say.

[fj11.5]

Excellent, thanks for the update mate

[keand3]

Cant wait to hear the result!
This might be the most tempting mod for me this winter

[Charlie-brm]

Just wondering if there has been progress on the projector / OEM lens fabrication project.

A friend put 2 HID projectors in a Suzuki TL1000 behind a replacement "lens" for the TL1000 he found online that has no lens facets or lines, ie plain high impact plastic like a helmet visor so the projector can do its thing without scattering.
I will tell you he spent a lot of trial cutting and fitting to bike plastic to mount the projectors in the frame and also sealing the replacement lens into the body work. But the results are scary bright and distinctive.

[movenon]

The donor headlight arrived today and the lens has already been removed. I'll stop by the molder tomorrow afternoon and see what they say.

How did you remove the lens ? Heat gun?
George

[Paul1965]

The donor headlight arrived today and the lens has already been removed. I'll stop by the molder tomorrow afternoon and see what they say.

How did you remove the lens ? Heat gun?
George

Hi George. Yes, just a few minutes with a heat gun and the adhesive was soft enough to pop the lens off. I've got a vacuum table made, just haven't had the time to build the frame necessary to hold the plastic.

[movenon]

So I guess you are going to end up with a clear lens as are on the newer cars and adapt a projector bulb on to the back side ?  Sounds interesting for sure.
George

[delarbreavous]

Found this on the internet,

May be usefull

http://www.theretrofitsource.com/closeouts.html

Alain

[simi_ed]

So I guess you are going to end up with a clear lens as are on the newer cars and adapt a projector bulb on to the back side ?  Sounds interesting for sure.
George

+1 on this.  Forgive me if I'm covering old ground here, but this seems important for this project.

I am sure you know that all of the focusing of the beam takes place in the fluted lens on a stock FJ headlight, while the newer "projector" lamps all use the reflector to focus the light.  It has to happen somewhere, or else it's gonna look like a 40 incandescent bulb in your table lamp, except brighter & LESS focused. 

[Paul1965]

So I guess you are going to end up with a clear lens as are on the newer cars and adapt a projector bulb on to the back side ?  Sounds interesting for sure.
George

George that's exactly correct. In fact, I'm almost toying with cutting the back completely off the old housing itself (where the bulb mounts) and make a new one that will allow the installation of 2 projectors instead of just one. I've been watching a dual kit on eBay for a while now and I'm pretty confident they'll both fit. It's just with all the other stuff I've got going on I haven't had the time to get around to making a frame and testing out my table and the whole vacuum forming process. In fact I might just say the heck with it and try fitting some high impact plastic directly to the fairing instead, but I don't think it will work as well.

[movenon]

Keep up the good work.  It all has to start somewhere.  Modifications are that way.  Working on a couple myself.  Sometimes its just takes a while to figure things out.  Persistence Paul..    Hell,  if it was easy it wouldn't be interesting.
George