Acrylic Stone Guards for Square Headlights
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- AngeloEvs
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Acrylic Stone Guards for Square Headlights
Given the expense and difficulty obtaining replacement square headlamps you may want to consider making and fitting acrylic stone guards. The pictures are self explanatory and the securing brackets can be made using a few basic tools. The acrylic lenses can be removed with or without the grille and there are no visible mods required to the grille.
The brackets are formed from aluminium strips as shown, (looks complicated but a good vice, 2mm drill bit and strips of plywood should be sufficient)
The brackets attach to the hidden flanges behind the grille as shown. The length of each bracket should be calculated to provide a clearance of at least 5mm from the face of each headlamp but also allow for clearance between the bracket/grille face to accommodate self tappers if used to secure the lenses to the bracket. Finally, colour match the brackets to the grille.
Cut the acrylic sheet (1.5mm to 2mm thick should suffice) on a band saw or a jig saw using a suitable blade (such as would be suitable for sheet metal). Approx. size is 135mm x 350mm. Finish/smooth the edges using a file (draw filing method) or scrape the edges with a steel rule.
On sunny/bright days the edges refract light and the outline of the acrylic lens can be seen from close up, if this bothers you then mask or paint them.
The lenses can be secured to the brackets using short self tappers (with a washer) or tie wraps. The fixing holes in the Acrylic need to have 'clearance' if using self tappers.
Depending on how your headlights are adjusted you may find that a very slight bend at the gap where the smaller headlight sits next to the larger one will help to maintain an even distance between protective lens and the headlamp, if so then this is best done by gently heating the acrylic over a strip heater and applying gentle pressure. Chances are that you won't need to do this unless you want things absolutely perfect!
Any questions, more details to make/form the brackets then happy to answer them………
The brackets are formed from aluminium strips as shown, (looks complicated but a good vice, 2mm drill bit and strips of plywood should be sufficient)
The brackets attach to the hidden flanges behind the grille as shown. The length of each bracket should be calculated to provide a clearance of at least 5mm from the face of each headlamp but also allow for clearance between the bracket/grille face to accommodate self tappers if used to secure the lenses to the bracket. Finally, colour match the brackets to the grille.
Cut the acrylic sheet (1.5mm to 2mm thick should suffice) on a band saw or a jig saw using a suitable blade (such as would be suitable for sheet metal). Approx. size is 135mm x 350mm. Finish/smooth the edges using a file (draw filing method) or scrape the edges with a steel rule.
On sunny/bright days the edges refract light and the outline of the acrylic lens can be seen from close up, if this bothers you then mask or paint them.
The lenses can be secured to the brackets using short self tappers (with a washer) or tie wraps. The fixing holes in the Acrylic need to have 'clearance' if using self tappers.
Depending on how your headlights are adjusted you may find that a very slight bend at the gap where the smaller headlight sits next to the larger one will help to maintain an even distance between protective lens and the headlamp, if so then this is best done by gently heating the acrylic over a strip heater and applying gentle pressure. Chances are that you won't need to do this unless you want things absolutely perfect!
Any questions, more details to make/form the brackets then happy to answer them………
1987 DG Karisma LPG with remodelled interior
- AngeloEvs
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Re: Acrylic Stone Guards for Square Headlights
If you want some let me know, got a spare set made up and may have just enough ally to make you some brackets too.......!
1987 DG Karisma LPG with remodelled interior
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Re: Acrylic Stone Guards for Square Headlights
I used to make those for motorcycle headlights, we used velcro 'dots' instead of brackets so you could simply remove them to wash the flies off.
Brackets look good though.
Brackets look good though.
2.1 DJ running on carb and LPG.
- lloyd
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Re: Acrylic Stone Guards for Square Headlights
That's a great idea! Very nicely done too! If you had any extra, I would be very interested in buying a set for our van.
Just a thought... Could you get polycarbonate for cover instead of acrylic??... it's almost unbreakable.
http://www.westwardplastics.co.uk/d_sel ... ycarbonate" onclick="window.open(this.href);return false;%&subcat2=Clear
Just a thought... Could you get polycarbonate for cover instead of acrylic??... it's almost unbreakable.
http://www.westwardplastics.co.uk/d_sel ... ycarbonate" onclick="window.open(this.href);return false;%&subcat2=Clear
88 1.9 gassed w/Westy conversion & Reimo topper
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- AngeloEvs
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Re: Acrylic Stone Guards for Square Headlights
I only have acrylic LLoyd but sent you a pm.
1987 DG Karisma LPG with remodelled interior
- lloyd
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Re: Acrylic Stone Guards for Square Headlights
Thanks mate! We must get together soon!
88 1.9 gassed w/Westy conversion & Reimo topper
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Re: Acrylic Stone Guards for Square Headlights
Great idea. I'm gonna order 2 of these
http://cgi.ebay.co.uk/ws/eBayISAPI.dll? ... K:MEWNX:IT" onclick="window.open(this.href);return false;
from fleabay and make myself some wallet sting protectors
http://cgi.ebay.co.uk/ws/eBayISAPI.dll? ... K:MEWNX:IT" onclick="window.open(this.href);return false;
from fleabay and make myself some wallet sting protectors
- orangescotty
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Re: Acrylic Stone Guards for Square Headlights
I was told that maestro head lamps fill to hole nice .......and cheap.
Re: Acrylic Stone Guards for Square Headlights
Here's mine fitted
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- AngeloEvs
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Re: Acrylic Stone Guards for Square Headlights
perfect!
1987 DG Karisma LPG with remodelled interior
Re: Acrylic Stone Guards for Square Headlights
are they compatable when you apply a colgan bra? as i do like
T25 Vanaru EJ25
Re: Acrylic Stone Guards for Square Headlights
Does the missus know? They work fine whatever clothes you like to wear
Re: Acrylic Stone Guards for Square Headlights
A big stone hit the front of the van the other day. I feared it had hit the headlights. It had but there was nothing other than a mark on the protectors
- donnieg
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Re: Acrylic Stone Guards for Square Headlights
They look great guys might try to make them myself