Homemade clear fog lights.......

Got5onit · #1 (**permalink**) 07-01-06, 06:59 PM

Just finished up the clear fog light mod. Loosened up the glue on the lenses by heating them up in the oven. Finished up with a heat gun. Purchased Two 11x14 sheets of lexan and traced a pattern with one of the removed lenses. Cut shapes out, sanded the edges, and glued with Silicone adhesive. The fog light housing is curved so I had to tape the lenses down with electrical tape overnight. Glued down pretty rock solid. Washed the car and sprayed the lenses, no leaks.

A couple of shots came out slightly blurry.
Opinions?

Black Ops · #2 (**permalink**) 07-01-06, 07:18 PM

WOW..it looks HOT!!! How about making some for us??

I was going to buy the STS-V ones but they want $200+ for them...what would you charge if you decided to make some for the CTS/CTS-V crew??

Staxxin · #3 (**permalink**) 07-01-06, 07:18 PM

LOOKS GREAT!!! On a side note, so do your rims. What did you do? Do you have a side photo?

v-ape · #4 (**permalink**) 07-01-06, 07:40 PM

how much do you charge

Got5onit · #5 (**permalink**) 07-01-06, 07:44 PM

Quote:

Originally Posted by Black Ops

WOW..it looks HOT!!! How about making some for us??

I was going to buy the STS-V ones but they want $200+ for them...what would you charge if you decided to make some for the CTS/CTS-V crew??

That was the main reason I did this. The ridiculous cost of the STS fog lights and the fact I prefer the clear look. You have to remove the fog light anyway, so I figured with a little elbow grease,making my own set wouldn't be hard to do.

Cost break down:

11x14 Lexan sheets from Home Depot - $5 each

Silicone Adhesive from Autozone - $5

Sandpaper - $??? Can't remember, it was some I had left over from another home project. Stuff is cheap.

If you have a dremel tool there is an attachment you can purchase to cut the lexan. I found this out by researching the web. I don't have a dremel tool, but my place of employment has a band saw and that's what I used. The lexan is not very thick, and I'm certain can be cut with any type of cheapo handsaw.

Also, there is a metal divider(I'm certain it's aluminum) inside the housing that separates the driving lights from the fog lights. This has to be removed and cut down just a bit. It pulls out with a firm tug. It's a very light piece of metal and is easily cut with a hacksaw.

The thought of making them and selling never crossed my mind. However, I am willing to help anyone who wants to do this and has any questions on this procedure.

urbanski · #6 (**permalink**) 07-01-06, 08:04 PM

paging WW

2004CTS · #7 (**permalink**) 07-01-06, 08:13 PM

Quote:

Originally Posted by Got5onit

The thought of making them and selling never crossed my mind. However, I am willing to help anyone who wants to do this and has any questions on this procedure.

Looks Awesome! Here are my questions:
1. What oven temperature did you use?
2. Did you set the oven on bake or broil (or something else)?
3. How long did you leave them in the oven?
4. Do you feel the lenses could have been cut off using a Dremel or similar type of tool?

wildwhl · #8 (**permalink**) 07-01-06, 08:17 PM

I'm on it

Guess I'll pull the fogs when I pull the bumper Monday to finish the MethInjection install...and make up a template.

How many do we need?

What was the thickness of the Lexan?

WW

Seattle CTS-V · #9 (**permalink**) 07-01-06, 09:02 PM

Looks awesome. I did the oven trick on the main headlights of my Acura. Worked very well to give me that clean look. Takes alot of time and patience though. Soak a towel first and set the lenses on that in the oven...just in case the metal bars get hot and decide to start melting the plastic.

Got5onit · #10 (**permalink**) 07-01-06, 09:08 PM

Quote:

Originally Posted by 2004CTS

Looks Awesome! Here are my questions:
1. What oven temperature did you use?
2. Did you set the oven on bake or broil (or something else)?
3. How long did you leave them in the oven?
4. Do you feel the lenses could have been cut off using a Dremel or similar type of tool?

Set the oven to Bake and PREHEAT at 350 (~6minutes).
When fully heated, turn OFF the oven. Place the fog light units on a baking pan, lens side down(damaging the lens is no big deal) and place in the oven for 10 minutes. Again, make sure the oven is OFF before doing this. You do not want to melt or warp the housing!!

Use a screw driver and slowly pry the lens out. Heat the edges with a heat gun or hair dryer when you feel it cooling off. USE GLOVES!! THEY WILL BE HOT! Don't ask me how I know.

The lexan is pretty flexible and seems pretty easy to cut. I read somewhere that it's 100 times stronger than glass and heat resistant up to 200deg(F). A cutting disk for a dremel or drill will certainly be sufficient.

Don't forget to pull the aluminum divider and cut it down. It sticks out and will get in the way when trying to place the new lens on.

The thickness of the 11x14 sheets at Home Depot were .93mm(1/8"). That's the only thickness I could find.

Also, my lens cut out was far from perfect. A few jagged edges, and not exactly round at the corners. But it was big enough to go to the edges of the housing, which is very important. Tape down the lexan to the housing and allow it to dry/cure overnight. The Adhesive sealant I bought had a 12hr curing time. Be sure to fill the entire outer gap with silicone adhesive. You don't want water leaks!

Chef · #11 (**permalink**) 07-01-06, 09:19 PM

Quote:

Set the oven to Bake and PREHEAT at 350 (~6minutes).
When fully heated, turn OFF the oven. Place the fog light units on a baking pan lens side down(damaging the lens is no big deal) and place in the oven for 10 minutes.

Use a screw driver and slowly pry the lens out. Heat the edges with a heat gun or hair dryer when you feel it cooling off. USE GLOVES!! THEY WILL BE HOT! Don't ask me how I know.

The lexan is pretty flexible and seems pretty easy to cut. I read somewhere that it's 100 times stronger than glass and heat resistant up to 200deg(F). A cutting disk for a dremel or drill will certainly be sufficient.

The thickness was .93mm(1/8").

Also, my lens cut out was far from perfect. A few jagged edges, and not exactly round at the corners. But it was big enough to go to the edges of the housing, which is very important. be sure to fill the entire outer gap with silicone adhesive. You don't want water leaks!

Ah, finally something a chef can relate to

Nice recipe!! Your tires and wheels look like mine

GS-D3's 275/40/18 rear, 245/45/18 front and powder coated black stock wheels?

chef out...

wildwhl · #12 (**permalink**) 07-01-06, 10:01 PM

Wouldn't everyone prefer a gray tinted material as opposed to clear? Just a thought...that's what I'll try with mine this weekend.

Also - how about a difraction(sp?) pattern engraved on the inside?

WW

Gordy Petrovski · #13 (**permalink**) 07-01-06, 11:20 PM

Man that looks kick ass Congrat's

rand49er · #14 (**permalink**) 07-02-06, 09:00 AM

Well, if there're any bad cooks out there, I just got my STS fogs from Lindsay on Thursday. When I install them, my stockers may be available to first guy/gal who gets his/hers over done.

Snif ... snif ... do I smell anything burning?

(Kinda wished I'd waited, now ... those homemade ones look pretty nice!)

Got5onit · #15 (**permalink**) 07-02-06, 01:41 PM

Quote:

Originally Posted by Staxxin

LOOKS GREAT!!! On a side note, so do your rims. What did you do? Do you have a side photo?

I had my stock wheels customized by a local wheel shop. The outer lip is polished and the spokes are painted black.

Here's a pic I took a few months ago:

Note the side marker light is now covered with black lens tint.