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Customizing Your NG900 or old 9-3 This forum contains all CUSTOMIZING related Q&A's, such as Lights (taillights, headlights, turn indicators, clear corners, etc), Interior and Exterior modifications, Wiring, Gauges and more.

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Old 03-20-2011, 11:07 PM   #1
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My attempt at clear headlights

So after installing the morimoto projector the output was a lot better than stock but did not have that amazing cutoff because of the fluted lens. I read the links that Zingzach posted about vacuum forming and figured I would give it a shot myself.

Here is the setup that i made


Here are some pulls




Here are some shots of the lens after several times messing up haha






These are some output shots. I have no camera skills so excuse the horrible pictures, also I did not aim the lights properly yet










I will try to aim the lights and take some more pictures in the next few days. But the clear lens makes an amazing difference!

The vacuum forming setup only cost me about $40 in parts. It was very simple to make. The tough part was the trial and error involved with working with the plastic.
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Old 03-21-2011, 12:04 AM   #2
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LOL thats awesome! You made it seem like this was a cake walk. If you ever plan on doing some pulls of c900 or 9k lenses, i might be interested if the price is right!
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Old 03-21-2011, 12:11 AM   #3
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Also you need to post pictures of how they look on the car
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Old 03-21-2011, 05:28 AM   #4
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Old 03-21-2011, 06:45 AM   #5
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Old 03-21-2011, 07:20 AM   #6
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Old 03-21-2011, 07:29 AM   #7
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pics of your car?
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Old 03-21-2011, 07:32 AM   #8
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How much would you want to make a pair to sell?

Nice work.
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Old 03-21-2011, 07:41 AM   #9
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Old 03-21-2011, 08:03 AM   #10
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do you have any plans to modify the molds so that the lenses use the factory mounting clips? the silicone you've got sealing the assembly kinda looks like crap. good for a first attempt, but that is something that would need to be resolved before a lot of people bought these, i think (assuming you are going to make more)
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Old 03-21-2011, 08:51 AM   #11
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Neat!
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Old 03-21-2011, 08:54 AM   #12
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Old 03-21-2011, 09:08 AM   #13
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I will post some pictures later today or tommorrow with the lights on the car. It's raining here today.

It was actually a lot easier than I thought it would be. As of now I have no plans to sell them. I would be more than willing to offer any advice or tips to anyone trying to vacuum form themselves.

Maybe with more trial and error I would be more willing to sell them. I wouldn't want to sell them to anyone until I know how they hold up to the weather. I would also want to know if they will yellow due to UV sun exposure.

Last edited by cymbolkid; 03-21-2011 at 09:16 AM.
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Old 03-21-2011, 09:11 AM   #14
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castortroy- Yea I tried several different pulls trying to get the factory clips that hold the light on to work. I can get an edge but it's not defined enough for the clips to hold onto. I didn't want to use the silcone, but it was the only option. I wanted to buy clear RTV silcone but pepboys only had black or red. With the lights on the car the silcone isn't really visable.
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Old 03-21-2011, 02:56 PM   #15
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do you have any plans to modify the molds so that the lenses use the factory mounting clips? the silicone you've got sealing the assembly kinda looks like crap. good for a first attempt, but that is something that would need to be resolved before a lot of people bought these, i think (assuming you are going to make more)
Clear silicone would probably fix that issue
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Old 03-21-2011, 02:58 PM   #16
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If you don't plan on selling these then you should definitely do a proper write up on how you made these lenses. Step by step directions would be awesome especially if you list all the tools you used, parts you bought etc etc
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Old 03-21-2011, 03:20 PM   #17
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i think the real question is how thick is the plastic and how UV resistant is it? i personally dont wanna put those on my car if the first stone kicked up in front of me is gonna go right through the lense.....

just things to consider!
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Old 03-21-2011, 06:24 PM   #18
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Good job, what material did you use to make the lens?
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Old 03-21-2011, 07:27 PM   #19
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That looks hella awesome man. Nice work. Agree ++ on the clear silicone. A how to or at least a general rundown would be killer.
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Old 03-21-2011, 09:43 PM   #20
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I have no problem detailing the steps i took to make the lights. Here is the link i used to make my vacuum former. It will atlaest give a general idea, until I make the guide.

Make a good, cheap, upgradeable sheet plastic vacuum former

I will try to put a guide together in the next few days. I have a few electrical side jobs that i am doing this week.

The plastic is acrylic plexiglass, thinkness 0.093. i bought the 18"x 24" plastic sheets at home depot about $8 a piece.

0.093 sounds really thin until you actually see the plastic. Its really tough, i did crack a few lenses only because i over heated them in the oven and when i vacuum formed them, the plastic was too thin. So when i tried to cut them it just broke. I think the plastic will hold up quite well, but only time will tell.

As for the UV resistance theres a guy over at hidplanet.com that has the same plastic on his car for a few years now with no problems.
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