Creating head light covers from scratch

I've been pondering how to do this for some time, how to create clear headlight covers from a pattern. In a perfect world I'd learn how to resin cast, but with time as limited as it is for me, that is a long term solution. In the mean time I'm wondering about alternative possibilities as to how to do this. I have a couple of projects in mind and I need to create bespoke head light covers for a modified Porsche 962C as well as a Nissan R90C conversion (from Tamiya R89C). I've read somewhere about a plastic that is used in some modeling circles (ships maybe?) that is designed for "ambient" vacforming (ie, heat without suction). Does this ring a bell with anyone?

Yup, a pattern (either scratch built or an existing kit part) can be used as a push mold.

I use K&S butyrate sheets for vac forming but it can be used just as well with push molds.

Yup, a pattern (either scratch built or an existing kit part) can be used as a push mold.

I use K&S butyrate sheets for vac forming but it can be used just as well with push molds.

How does one push mold? Is it as simple as heating the plastic sheet and then drawing it over your pattern/form?

How does one push mold? Is it as simple as heating the plastic sheet and then drawing it over your pattern/form?
Mike, check out the last couple of pages of my 612 China Tour thread in the street WIP section. I made new headlight covers for the Scaglietti using smash forming and there are some photos of how I did it.

Hope that helps you some.

Exactly . . . Quick, cheap and no hassle. . . :)

Patterns can be made out of anything really. I've used just about everything under the sun. Plaster, Fimo, wood, resin', etc.

Mike, check out the last couple of pages of my 612 China Tour thread in the street WIP section. I made new headlight covers for the Scaglietti using smash forming and there are some photos of how I did it.

Hope that helps you some.

:thinkerg: . . I knew I saw an excellent example that was recently posted. . .

Mike, check out the last couple of pages of my 612 China Tour thread in the street WIP section. I made new headlight covers for the Scaglietti using smash forming and there are some photos of how I did it.

Hope that helps you some.

Could you point me in the direction? Did a search of 612 China Tour and came up with a WIP thread that only had two pages.

Could you point me in the direction? Did a search of 612 China Tour and came up with a WIP thread that only had two pages.

Try this one (http://www.automotiveforums.com/vbulletin/showthread.php?t=620906). If nothing else, it's a fun read....

Try this one (http://www.automotiveforums.com/vbulletin/showthread.php?t=620906). If nothing else, it's a fun read....

Thanks, that's the one, about page 12 or so.

To Klutz, you push formed straight over the existing headlight covers using the clay/wax for support? Do you have to (mold) release your form/pattern?

it looks like the clear acetate was heated and formed over the existing part?

you push formed straight over the existing headlight covers using the clay/wax for support? Do you have to (mold) release your form/pattern?
Exactly that although you could use anything as a mold. In this case my goal was to get thinner clear parts.

No mold release is necessary at all - nothing sticks to anything else :)

Mike, also check out JayKay's 1/43 Porsche here: http://www.automotiveforums.com/vbulletin/showthread.php?t=763905

You can see how he used the body to make a new mold to form the clear part.

Apart from anything else, it's a great read and very educational.

Mike

What 962 are you doing? As long as it's not the Lloyd GTI or an Almeras car a standard cover should fit as far as i can tell.
I bought the vacform sheet from the Hiro 962 to replace the moulded in Tamiya glass pieces for only a couple of Euros.
That has the added benefit of giving you new thinner glass pieces for windscreen and side windows as well...

Mike

What 962 are you doing? As long as it's not the Lloyd GTI or an Almeras car a standard cover should fit as far as i can tell.
I bought the vacform sheet from the Hiro 962 to replace the moulded in Tamiya glass pieces for only a couple of Euros.
That has the added benefit of giving you new thinner glass pieces for windscreen and side windows as well...

Joest 962C from Daytona 1991. Many teams ran highly modified 956 noses in order to lengthen the front overhang and move the rear wing forward in order to move the center of pressure forward while still maintaining the 4800 mm maximum length. I've studied the Joest car for some time and spoken with their technical director (same guy involved with the Audi R10). He's provided the as-homologated front and rear overhang dimensions so I know how much longer to make the nose (and by how much to shorten the tail). Just have the headlight covers to deal with. I've flirted with using 956 covers and in fact might go back to them. Issue is cutom fitting them as well as bondo "bedding" them into the headlight bucket without ruining them. I've started and stopped this build so many times (started with Hasegawa then I noticed their major gaff in the side window dimensions so I scrapped all my work up to that point and went on to other things. Within the past 6 months I've started anew using the Tamiya 962 kit and I'm currently building the modified tail), I just want to finish it so I try and avoid any areas that will give me grief and halt me. Having said that, I'm ultimately willing to compromise and had been really considering just using 962 covers.

Here's my work from 2005 on the Hasegawa before I decided to back track on all of it:

http://www.mulsannescorner.com/images/Porsche962-13.jpg

http://www.mulsannescorner.com/images/Porsche962-14.jpg

Here's the nose lengthened and with the 956 headlight covers placed:

http://www.mulsannescorner.com/images/Porsche962-15.jpg

Anyhow, while I'm redoing the tail, I'm trying to come up with better ways to redo the nose inasmuch as the headlight covers are concerned.

BTW, that's the Hasegawa kit with the Tamiya underfloor attached. While that conversion was really straight forward, the further idea was to then add the Tamiya 956 engine details for a full detail 962C. I give myself too many headaches I think...

That's what the hobby's for...creating headaches where you didn't have any:-) Trust me...i have many of such projects "planned", including full detail 962's.
I fell in love with the '93 Joest after getting great pictures from Remi. Got some decals...now i need time :-)
BTW....do you have any engine pictures of the Loewenbraeu 962 by any chance? That's another one i'd like to do full detail!

But on to your project. Judging from your picture and comparing it with reference pictures i'd say your head light covers are too long ( towards the front ). I just had a look at the HIRO vacform pieces and i think they might be usable with a bit of cutting sanding and polishing...but i can't guarantee of course :-)
On the other hand you could do your own by forming them with the method Klutz used on his 612 ( or me on the little GT1 ). If the 956 covers are not big enough you could add material with polyester body filler, sand smooth and then do it. That will destroy them for later use but you should be able to figure out how the forming thing works and then make as many as you need to get the shape you need:-) Try it!

That's what the hobby's for...creating headaches where you didn't have any:-) Trust me...i have many of such projects "planned", including full detail 962's.
I fell in love with the '93 Joest after getting great pictures from Remi. Got some decals...now i need time :-)
BTW....do you have any engine pictures of the Loewenbraeu 962 by any chance? That's another one i'd like to do full detail!

But on to your project. Judging from your picture and comparing it with reference pictures i'd say your head light covers are too long ( towards the front ). I just had a look at the HIRO vacform pieces and i think they might be usable with a bit of cutting sanding and polishing...but i can't guarantee of course :-)
On the other hand you could do your own by forming them with the method Klutz used on his 612 ( or me on the little GT1 ). If the 956 covers are not big enough you could add material with polyester body filler, sand smooth and then do it. That will destroy them for later use but you should be able to figure out how the forming thing works and then make as many as you need to get the shape you need:-) Try it!

Yes, the '93 Joest car is a nice one too...

I don't believe I have any shots of the fully air cooled single turbo IMSA 962 engine other than the '89 Busby car. So while it is essentially the same engine (sort of--there were a number of garden variety IMSA air cooled 962 engines, 2.8 liter, 3.0, 3.2, etc., and all were closely tied to what the regulations were at the time) as the Holbert 962, teams did so much moving around of the components (turbos, wastegates, intercoolers) that each engine was essentially bespoke to each car/team.

Yes, the glass area of the 956 covers is too long, but they have the correct side profile (given the nose extension) and would then be masked and painted reducing the glass area to more appropriate 962 size if that makes any sense.

I've got some ideas but as always, other things on the burner at the moment...might be a while before I get back to this.

I use Squadron Thermaform for windshields, head light covers, and many other clear parts.

Yeah...the variety of IMSA 962 engines is my exact problem! That's why i was asking specifically for the Holbert:-) I have a few but not really enough.
I'm not even looking for a specific chassis, year or race...just one layout that was used at some point. The restored car would do. I had hopes for Rennsport III...but nothing. I was told they kept the car shut all the time :-(

Anyway.... show us updates when you get back on your Joest, please!

Yeah...the variety of IMSA 962 engines is my exact problem! That's why i was asking specifically for the Holbert:-) I have a few but not really enough.
I'm not even looking for a specific chassis, year or race...just one layout that was used at some point. The restored car would do. I had hopes for Rennsport III...but nothing. I was told they kept the car shut all the time :-(

Anyway.... show us updates when you get back on your Joest, please!

For now I'm taking it easy doing...a 1/350 submarine, my new obsession...I'll get back the Joest next...maybe. You mentioned buying from MFH the vac formed glass parts out of their 962 kit. How did you contact them? I have my eye on the engine details...would love to cast the ones out of my kit, just so I have a 962 engine to slot into each of my Tamiya 962 kits (making them full detail!), but for now I think that too ambitious for me. Wonder if they would sell me the engine block bits, turbos, and gearbox. Their website is a nightmare to navigate, wondering how you contacted them.