k-existence
09-24-2014, 11:39 PM
Hey, I thought I'd share my most recent project since it turned out surprisingly well and might be helpful for other members.
One of aftermarket fog light lense melted and became an eyesore. It overheated since I applied two layers of colored film on it. I wanted to avoid film this time since the colour is too light with one layer and the film bubbles after time.
http://i.imgur.com/JbtHD14l.jpg
I took the idea of replacing the lenses from someone on the rxs forums (http://forums.clubrsx.com/showthread.php?t=692924). They did a good walk-through and here is my adaptation with painting a tint on it.
Materials
Lexan Plexiglass ($12 for a 11x14 sheet from Home Depot) - This stuff is strong and bulletproof.
Pebeo Vitrail Stain Glass Paint ($6-12 from Curry's or Michaels) -- You can also get red, yellow and blue transparent spray paint from Home Depot if you want to use those standard colours.
Paint Brush (I recommend a soft bristle craft brush, $2 from Michaels. I tried a sponge brush but it made bubbles and a plastic bristle brush showed too much strokes)
Permatex Silicone Adhesive Sealant (Home Depot for about $5)
Fog lights housing
LED bulbs (optional -- I decided to switch over to prevent overheating again. I heard they aren't as bright as halogens... But the ones I got are pretty damn bright! Besides my fogs are more for aesthetics than practicality. I bought mine from aliexpress for $21 (http://www.aliexpress.com/snapshot/6214692107.html).
Step 1
Uninstall your fogs and take apart the fog light housing.
Use pliers to rip apart your old lenses. If possible keep one full piece to trace new lenses.
Clean your bulb reflectors. I used CLR to get most of the grime and dirt off.
Clean the rest of the housing while you're at it with some car wash soap.
http://i.imgur.com/XWKNs1dl.jpg http://i.imgur.com/Hoyx08El.jpg
Step 2
Trace the shape of your lens. Use the old lens or the bulb reflectors.
Do not remove the lexan plastic film protectors until painting and reassembly. This is important to keep the lens clean.
Trace a couple because you might screw up cutting, sanding or painting.
http://i.imgur.com/Qs79UYY.jpg
Step 3
Using a jigsaw, clamps and a work table, cut them carefully but it doesn't have to be too precise.
Sand the edges to fit the bulb reflectors perfectly.
http://i.imgur.com/N0gbWeO.jpg?1
Step 4
Using lexan scraps, test the paint colour, how many coats and practice painting to avoid strokes (this depends on your brush)
The best brush was this $2 craft soft bristle brush from Michaels -- sponge and plastic bristles showed strokes and bubbled too much.
Dipping and pouring the paint on is not a good idea... I tried it and its too blotchy and thick.
I tested 1-2coats and liked the 1 coat best --be sure to view it with the lights off and a flashlight behind it to see how it to looks at night.
The color dries pretty close to the color you see when you apply it.
You will need turpineant substitute ($10) to wash your brush or just be like me a buy new brushes for $2 each. Do not use an old brush on your final lens because there will be dust specks.
Step 5
After all that testing, it's time to paint the lens.
Make little handles with tape on the front "facing out" side. This will help you hold on to the lens while you paint the back "facing in" side. --- See photo below
Flick your new brush a few times to make sure there is no dust or hairs. I literally took mine out of the packaging seconds before painting to prevent dust collection.
Pour the paint in a clean plastic cup (again... keep things dust-free)
Peel the lexan protection film from the side that is facing inside the housing and start painting.
Keep your coats and strokes consistent so both lens will be the same.
Paint a couple in case some turn out better than the others.
Put your painted lens under a Tupperware or something to prevent dust and stuff falling on the paint while it dries.
Leave them to cure for 24-48 hours.
http://i.imgur.com/U02ldzUl.jpg
Step 6
Follow the rim of the bulb reflectors and fill it with silicone. Apply the painted side to be the facing inside of the bulb reflectors. Use clamps to hold it in place and wait for another 24 hours.
http://i.imgur.com/eitXfEp.jpg
Step 7
Remove the clamps and the lexan film protector on the front.
Reassemble the housing and reinstall it back in your car with the new LED bulbs.
http://i.imgur.com/UoNT33D.jpg
I love the way it turned out and the tint looks way better than the original film. I did test the heat resistance of the Lexan and the paint by putting it under a lighter flame. The paint stayed on and after a while the Lexan did melt. But what plastic wouldn't under a direct flame. The LED bulbs are cooler so they should help. I'm just worried about moisture. Hope it holds up!
I did experience my LED being really dim on one side after the first day of install... but the next day it was fine... it might just be my wiring or fuse...:bang
http://i.imgur.com/qlIE9rv.jpg
http://i.imgur.com/BSZRACv.jpg
Let me know if you guys have questions.
One of aftermarket fog light lense melted and became an eyesore. It overheated since I applied two layers of colored film on it. I wanted to avoid film this time since the colour is too light with one layer and the film bubbles after time.
http://i.imgur.com/JbtHD14l.jpg
I took the idea of replacing the lenses from someone on the rxs forums (http://forums.clubrsx.com/showthread.php?t=692924). They did a good walk-through and here is my adaptation with painting a tint on it.
Materials
Lexan Plexiglass ($12 for a 11x14 sheet from Home Depot) - This stuff is strong and bulletproof.
Pebeo Vitrail Stain Glass Paint ($6-12 from Curry's or Michaels) -- You can also get red, yellow and blue transparent spray paint from Home Depot if you want to use those standard colours.
Paint Brush (I recommend a soft bristle craft brush, $2 from Michaels. I tried a sponge brush but it made bubbles and a plastic bristle brush showed too much strokes)
Permatex Silicone Adhesive Sealant (Home Depot for about $5)
Fog lights housing
LED bulbs (optional -- I decided to switch over to prevent overheating again. I heard they aren't as bright as halogens... But the ones I got are pretty damn bright! Besides my fogs are more for aesthetics than practicality. I bought mine from aliexpress for $21 (http://www.aliexpress.com/snapshot/6214692107.html).
Step 1
Uninstall your fogs and take apart the fog light housing.
Use pliers to rip apart your old lenses. If possible keep one full piece to trace new lenses.
Clean your bulb reflectors. I used CLR to get most of the grime and dirt off.
Clean the rest of the housing while you're at it with some car wash soap.
http://i.imgur.com/XWKNs1dl.jpg http://i.imgur.com/Hoyx08El.jpg
Step 2
Trace the shape of your lens. Use the old lens or the bulb reflectors.
Do not remove the lexan plastic film protectors until painting and reassembly. This is important to keep the lens clean.
Trace a couple because you might screw up cutting, sanding or painting.
http://i.imgur.com/Qs79UYY.jpg
Step 3
Using a jigsaw, clamps and a work table, cut them carefully but it doesn't have to be too precise.
Sand the edges to fit the bulb reflectors perfectly.
http://i.imgur.com/N0gbWeO.jpg?1
Step 4
Using lexan scraps, test the paint colour, how many coats and practice painting to avoid strokes (this depends on your brush)
The best brush was this $2 craft soft bristle brush from Michaels -- sponge and plastic bristles showed strokes and bubbled too much.
Dipping and pouring the paint on is not a good idea... I tried it and its too blotchy and thick.
I tested 1-2coats and liked the 1 coat best --be sure to view it with the lights off and a flashlight behind it to see how it to looks at night.
The color dries pretty close to the color you see when you apply it.
You will need turpineant substitute ($10) to wash your brush or just be like me a buy new brushes for $2 each. Do not use an old brush on your final lens because there will be dust specks.
Step 5
After all that testing, it's time to paint the lens.
Make little handles with tape on the front "facing out" side. This will help you hold on to the lens while you paint the back "facing in" side. --- See photo below
Flick your new brush a few times to make sure there is no dust or hairs. I literally took mine out of the packaging seconds before painting to prevent dust collection.
Pour the paint in a clean plastic cup (again... keep things dust-free)
Peel the lexan protection film from the side that is facing inside the housing and start painting.
Keep your coats and strokes consistent so both lens will be the same.
Paint a couple in case some turn out better than the others.
Put your painted lens under a Tupperware or something to prevent dust and stuff falling on the paint while it dries.
Leave them to cure for 24-48 hours.
http://i.imgur.com/U02ldzUl.jpg
Step 6
Follow the rim of the bulb reflectors and fill it with silicone. Apply the painted side to be the facing inside of the bulb reflectors. Use clamps to hold it in place and wait for another 24 hours.
http://i.imgur.com/eitXfEp.jpg
Step 7
Remove the clamps and the lexan film protector on the front.
Reassemble the housing and reinstall it back in your car with the new LED bulbs.
http://i.imgur.com/UoNT33D.jpg
I love the way it turned out and the tint looks way better than the original film. I did test the heat resistance of the Lexan and the paint by putting it under a lighter flame. The paint stayed on and after a while the Lexan did melt. But what plastic wouldn't under a direct flame. The LED bulbs are cooler so they should help. I'm just worried about moisture. Hope it holds up!
I did experience my LED being really dim on one side after the first day of install... but the next day it was fine... it might just be my wiring or fuse...:bang
http://i.imgur.com/qlIE9rv.jpg
http://i.imgur.com/BSZRACv.jpg
Let me know if you guys have questions.