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Making a new shape headlight insert, what should I use ?


DodgyRog
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I have been meaning to refurb my headlights forever and have been playing around with different Silver/Chrome paints, trying to get a finish I would be happy with and failing

 

Well now I have to paint the bonnet I have decided to try something different with my headlights and I am going to try and build up the inserts to be something like the ABFlug insert, but with the sidelight still

ABFlug

image

 

and OEM pre Facelift

image

 

Can someone tell me what would be the best material to use, I was going to use Fibreglass as a builder then a layer of filler to get a decent finish, but will the heat from all the HID's cause issues with this

 

The idea would be to smooth in the sidelight pod, so it's not such a blob

 

Cheers Rog

Edited by DodgyRog (see edit history)
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At a quick glance the way i would do it is as follows.

Drill a small hole at the base where you want the built up part to end and one up the top where you want it to start. Use some brazing rod to link the holes.

You should have what looks like a washing line on a slope now.

Now use some fg matting to drape over it to make the shape and continue this until happy.

Now to get a smoother finish lay some fg tissue to smooth it out a bit.

Once this is all done, finish it with stoppers rather than filler as this does the same thing but is a bit more vibration resistant and less prone to crack over time.

Now sand it and paint it.

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