disgruntlednut

So the project turned out to be more of a hassle than what I thought it would be...

Step 1: Cut away the old, hazed, pitted lens with a dremel.

Step 2: Trace outline onto sheet of lexan and cut (pain in the ass, takes time and a lot of patience not to break or scratch it)

Step 3: Sand down the exposed outer edge of the roadlamp housing and match up the freshly cut lexan. Sand down rough edges on lexan lens.

Step 4: VERY thin bead of epoxy around sanded edge of roadlamp housing (Too much and it'll ooze out into the housing as I learned the hard way). Use zip-ties or C-clamps to hold lens to housing. Housing is curved, lexan sheet isnt. Keep a steady hand and only set the new lens down once. The more you move it around, the wider the bead of epoxy will spread.

Step 5: After epoxy hardens, use plenty of silicone to keep water out (I wasn't generous enough the first time and had to do it again)

Step 6: Mask off lens except for outer edges where you can see the epoxy through the clear lexan.

Step 7: Sand down exposed front lexan edge (1/4 - 1/2 inch) and paint with color of choice.

Step 8: Wait for paint to dry, carefully remove masking tape, and re-install roadlamps.








The old plastic cover







I'll get some night pics up soon!

disgruntlednut

Sorry, iPhone = Horrible pictures and I tried reducing the image size 3 times on photobucket and its not changing

nf3d0149ab

iTrader: (5)

I love the rolling shots!!!

Okay...nice to see this completed and thanks for the DIY.

Do you hope to be able to run some higher wattage bulbs now?

evan03CL

very nice! been looking to re-do the lense on my roadlamps as well. how much did the project cost?

i also like the black border around them where u painted.

nf3d0149ab

iTrader: (5)

+1 on the black border.

disgruntlednut

no plans for higher wattage bulbs yet, maybe HIDs after awhile. Depends on how well the lexan holds up to the elements. Total cost was ridiculously cheap. Sheet of lexan or acrylic from home depot cost under 4 bucks (enough to do 4 roadlams or mess up twice) and a couple bucks apiece for sandpaper epoxy silicone and paint. Pictures don't do them justice. They look amazing with cleared headlights and LEDs

rondog

iTrader: (1)

wow, didn't think there would be a big diffeence, but those shots with the crystal clear lense and black border look pretty damn good!

nspec_ya4

iTrader: (38)

stole my idea

well kinda (didnt include the lexan) I had plexiglass in mind.

urs came out really nice.

nf3d0149ab

iTrader: (5)

I hope you can make HID's work....

cltypeSLOW

excellent job.

02CLNOS

looks grate

CL-Slick

iTrader: (7)

I would like to get a set for my '03, black out the housing, and hook up HIDs in them. What do you guys think?

nf3d0149ab

iTrader: (5)

^ That's what we are going to be waiting to find out.

The issue I think is going to be the depth of the roadlamps.

They are much too shallow but I'm hoping it'll work without any "meltage"

nbennettksu

iTrader: (2)

nice touch. wrong side of the road

nf3d0149ab

iTrader: (5)

Double Yellow...!

disgruntlednut

HIDs can not, and will not work in the OEM housing even with a lexan or acrylic front lens. I've got burn marks in the foil in both housings from the standard 5W bulbs... HIDs are 35W, therefore, they'll turn the foil and possibly the plastic itself into goo. Not only that, but the way its designed, you won't get light output... just glare.

Rolling shots courtesy of o2cls.
It was a quiet residential area, could see pretty far ahead and wasnt going more than 15-20mph.

RYANGP

great job, i love that rolling shot too

AnthraciteBeast

iTrader: (3)

Great job!

WE WANT HID FOG LIGHTS! Lol

disgruntlednut

Night-time Pics:

evan03CL

they look very nice and clear at night. great!

GRNMCHN03cl

Sooo much blue!! wow

CL-Slick

iTrader: (7)

What bulbs are those? They would look good with my 8500k xenons.

02CLNOS

are you running the 194 piaa fogs?

disgruntlednut

LEDs from superbrightleds.com.
1 LED forward and 4 around to light up the housing better. The second pic I posted probably shows the color of the roadlamp housing most accurately.

nf3d0149ab

iTrader: (5)

Looks good man.

AMGala

iTrader: (4)

Well done! Its been a hot topic over at the 2G TL boards because I posted up a template that people could use for the Lexan. The next CLer that does this should trace the Lexan piece onto a piece of paper (after you have gotten the correct shape for the road lamp), scan it and post it up. It will be very helpful for anyone who will do this in the future.

deematic

iTrader: (1)

Very nice mod, top notch.

nf3d0149ab

iTrader: (5)

Good idea.

jaysizzlecity

yo that's hot..........

jaysizzlecity

My old CLs had 21 LED

disgruntlednut

Well, just over 1 year later, a rock or something hit one of the roadlamps and busted it... The other one has still held up well... no chips, no hazing or discoloration, and no condensation (Too bad the same can't be said about my headlights...) Haven't decided if I want to make a new one or just pop in the plastic inserts and be done with it.

nf3d0149ab

iTrader: (5)

That sucks man...

MrFluffy

I tried this but couldnt get the border right you got way more patients then me but I hate the way our road lamps look compared to the headlights they look cheap but yours match perfect

StreetKA

iTrader: (8)

how much would you want to fabricate a set for me ? :P but the paint inside would reflective black

disgruntlednut

Just finished. I compared the new one to the one that hadn't broken... Its held up to the elements surprisingly well. No hazing, a couple of small nicks from rocks and sand, but still crystal clear.