Then, a longer project. I didn't know if I could get fog lamp lenses, so I planned ahead. Before I cut out the lens holes, I made a mold of the area with fiberglass, which created a reverse image. I don't know why I didn't just use the plugs I cut out to make the holes, but I do remember cutting up the plugs pretty bad as I cut them out. Anyway, I then made positive images from the negatives, cleaned and sanded them, including gel coating and finish sanding, then thermoformed a few lenses. I must say they turned out terrific. I can make more if anyone is interested. However, they are a pretty specific size, so you'd need to cut the holes using the lenses as templates to make them perfect. I used H's fog lamp buckets.
Making a positive image mold from the negatives:
Positive images getting cleaned up:
Gel coated and ready for final sanding and hot plastic:
Professional drape thermoforming setup:
Finished product turned out perfect. How in the hell do you take a photo of something clear?!??
Made the doodads that anchor the top of the door to the body. Don't know what those are called...
Anyway, didn't think I would be able to find the real thing. I realized later after looking at photos that I was supposed to put three mounting holes in it instead of just two. I'll probably leave as-is unless I decide later to fill and re-drill.
Anyway, I thought they turned out pretty good for a hack machinist.