Fiberglass C-Series headlight lens

[Wheel Horse 3D 3,795]

1 minute ago, cschannuth said:

The lens is actually perfectly flat and that’s how I measured it so it should be pretty accurate. The holes also have a bevel to allow the screws to mount flush with the face of the lens.

Thanks Craig that's perfect.One clarification, that is BETWEEN the holes, or on center?

[Wheel Horse 3D 3,795]

Is it my imagination, or is it usually the left headlight that overheats the lens? Seems like every one I've seen its been the left one.

[cschannuth 3,816]

25 minutes ago, Wheel Horse 3D said:

BETWEEN the holes, or on center

That measurement was center to center. 

[roadapples 6,983]

Like Eric, mine isn't installed yet...

[Wheel Horse 3D 3,795]

So what would we consider a good test? I'm willin' to melt a lens just to know or at least get a rule of thumb. I realize different setups will be different, but at least I can try to find a benchmark..

I'm actually surprised this is a problem across so many year models. You would have thought as some point they would have added some venting or a heatsink or somethin'. And since I currently have the parts and replaceable lenses lets see if we can cure the problem! Either by ensuring we have a high enough temp material for the lenses, or maybe try some other modification.

Edited May 14, 2021 by Wheel Horse 3D

[WheelhorseBob 1,549]

5 hours ago, Wheel Horse 3D said:

It'll be close. Anyone able to get a horizontal hole spacing in mm to go with that?

I know it’s hard to tell from the picture but on the broken end you will have a portion of both the upper and lower holes. I think it will be enough to get the spacing correct. 

[Wheel Horse 3D 3,795]

Thanks Bob! That will be another reference to compare and be sure were on track!

[Wheel Horse 3D 3,795]

30 minutes ago, Wheel Horse 3D said:

So what would we consider a good test? I'm willin' to melt a lens just to know or at least get a rule of thumb. I realize different setups will be different, but at least I can try to find a benchmark..

I'm actually surprised this is a problem across so many year models. You would have thought as some point they would have added some venting or a heatsink or somethin'. And since I currently have the parts and replaceable lenses lets see if we can cure the problem! Either by ensuring we have a high enough temp material for the lenses, or maybe try some other modification.

I went ahead and created a Headlight lens melting test topic.

[roadapples 6,983]

1 hour ago, Wheel Horse 3D said:

I went ahead and created a Headlight lens melting test topic.

I'm not concerned. I'm not going backwards from LED's....

[Wheel Horse 3D 3,795]

Got Bob's lens in today! But looks like it got flattened in shipment and cracked in half. But good thing is all the pieces are still there and Ill start modeling on this tomorrow! This, even cracked, has a definate curve. Wonder if they were molded that way, or get stuck that way as they get brittle over time.

[EricF 589]

Looks like you've got enough of the mounting holes in the broken end to at least get a measurement off of them, and then add on the measurement you get from the good end to get a pretty close estimate on the whole thing's dimensions. A little tougher accounting for the bend, but still doable figuring the linear measurement along the edge. I'd guess that the original plastic is some sort of hard acrylic that was molded close to the curve it would take when mounted -- that kind of plastic tended to be a bit brittle right from the get-go, so molding it flat and wrapping it to the shape of the hood would have been a no-no. Modern stuff that stays flexible will make it easier to print as a flat piece once the dimensions are dialed-in.

[cschannuth 3,816]

1 hour ago, Wheel Horse 3D said:

Wonder if they were molded that way, or get stuck that way as they get brittle over time.

The NOS one I got from Steve @wh500special is perfectly flat.  I don’t know if they came flat or if it just flattened out being stored for so many years.

[WheelhorseBob 1,549]

Dang usps! I even sprang for a bubble rap envelop. Well I hope it is of use to you,?sounds like a few folks need them.

[ebinmaine 67,618]

9 minutes ago, WheelhorseBob said:

bubble

Seems like you should have upgraded to Armor plated. 

[Wheel Horse 3D 3,795]

38 minutes ago, WheelhorseBob said:

Dang usps! I even sprang for a bubble rap envelop. Well I hope it is of use to you,?sounds like a few folks need them.

Itll do just great. Thank you for sharing! And as far as the curve, i have the measuements fron the flat one provided, and I can eyeball any curvature alignment pretty well.

[Wheel Horse 3D 3,795]

1 hour ago, ebinmaine said:

Seems like you should have upgraded to Armor plated. 

A Brinks truck with a safe and motorcycle security like "The italian job"!

[Wheel Horse 3D 3,795]

Drum roll please! .............

TA DAAA!!!!!

[Wheel Horse 3D 3,795]

Anyone like to see any custom additions?

[cschannuth 3,816]

11 minutes ago, Wheel Horse 3D said:

Anyone like to see any custom additions?

Looks great. Is there anyway the clear opening can be as large as the original?

[Wheel Horse 3D 3,795]

4 minutes ago, cschannuth said:

Looks great. Is there anyway the clear opening can be as large as the original?

Due to the screw holes we lose a bit on either side. and the end cuts were left square to simplify cutting the plexi, especially since this portion overlaps the hood anyway. We could tweak the end cuts so they are at a similar angle lemme see if I can tweak that and see how it looks, just a little more difficult on the plexi cutting.

 

[Wheel Horse 3D 3,795]

That gained a little bit more opening.

[Wheel Horse 3D 3,795]

Whoops, upside down pic lol.

[Wheel Horse 3D 3,795]

Thats better.

[Wheel Horse 3D 3,795]

Since i happened to load some clear PETG on Max for his first test, lemme stack this bezel and see what it looks like in the "clear" filament.

Cant hurt!

[Wheel Horse 3D 3,795]

Hmmmmmm