Making a tail light lens copy

[robedney]

Mildred came with one good tail light lens. Although new ones are available, they are pricey. Also, Mildred's existing lens is solid red, while the new replacements seem to all be red/amber, meaning I'd need two new ones. Over here in the US that's a fair outlay. So, as I have all the stuff on hand, I decided to have a try at making a copy just for fun (the left/right lenses are the same on Mildred).

I did this quickly, not using the right sort of casting plaster, force drying it, skipping much of the finishing process, etc. As a result the outcome is a bit rough, but works as a proof of concept. Although the shape in the pic looks a bit distorted it's perfect (the distortion is the camera angle/lens).



If I did this again using the right casting plaster and properly finished the mold, I could make a virtually exact copy of the original. I cast it out of epoxy resin with a clear red colorant. I'm thinking I might make a pair of clear lenses and use red LED's instead of bulbs. Ought to be a good deal more visible, if a bit obnoxious. I might also add a nice pair of interlinking M's to the mold for the Morris Minor bit.

If anyone wants details I'll write up the process with pics. The cost of all the supplied/materials would be cheaper than a pair of new lenses even if I didn't have the stuff around already. The application here, of course, would be for lenses that are no longer obtainable -- which fortunately doesn't include us moggie folk.

[charlie_morris_minor]

If anyone wants details I'll write up the process with pics.

yes please

[simmitc]

Ditto. Looks as good as anything being sold, and will probably last a damn sight better too.

[bmcecosse]

Very interesting - can you post up the details here? Do a step by step write up ??

[Alex'n'Ane]

Agreed, look very god, would be interested to see how effective the amber bulb showing through these would be, as imo they look a lot nicer single colour. And clear ones would match the clear front indicator/sidelights a few of us have now too.

[RobThomas]

The very early 1948/49 ones are not obtainable. I can make the metal bits but not lenses.

Carlo P. Are you listening to this?

[mike.perry]

Demand for the 1948 L 482 lights must be very small and there are a few lenses around

[WPR678B]

The very early 1948/49 ones are not obtainable. I can make the metal bits but not lenses.

Carlo P. Are you listening to this?

LOL! Yes, i am!
I think i have enough lenses to supply every surviving Minor that came from the factory with these lights!!
Obviously i need to keep some for my early one though

[Iain Hall]

Looks nice but wouldn't you be better off using some of the silicone moulding stuff ? Gives a better finish and has enough flexibility to facilitate easy removal once the epoxy is set especially if you do it properly and make a two piece mould.

that said making some clear lenses for the earlier tail lights sounds like a good idea to me because then it would be possible to have both the stop tail and indicators (by using Led's) without having to have the butt ugly lights like the ones fitted to the later minors.
Hmm I think that I will have to look into that as a a little side project, thanks for the inspiration