06-17-2014, 04:31 AM
I wanted to upgrade the headlights on 512 like I had done on 390. However, the ECE code headlights to replace the Ford pickup truck lights were no longer available. So, I had a wild dream and decided to remodel the front cap to look more like the later models.
Newell uses a 90 mm Hella sealed unit. You can source those from Rallylights.com. I decided to go whole hog and install the bixenon. Translated into English this means I used HID lighting for the low and high beam.
Step one was to cut out the out headlights and the recessed fiberglass that surrounded the lights. That is picture one. [attachment=2245] Pictures two is a shot of prefabbing some flexible fiberglass sheeting to give me something to start filling the hole.[attachment=2246] I simply put wax paper down on a smooth surface, wet some fiberglass cloth with resin, and waited for it to cure.
I needed some round tubes to act as the recesses for the round units. So I found appropriate sized pipe or tubing, waxed the outside of the pipe, and wrapped it with resin saturated cloth. When that cured I had fiberglass tubing to make the recesses for the lights and new round blinkers. [attachment=2247]
I have added a few pics that show building the layers of fiberglas in place to fill in the hole. By the way the fiberglass on the front cap is 3/4 inch thick in this section. That's a lot of fiberglass. Two days worth :-).[attachment=2248]
After the glass was almost flush with the rest of the surface, I used bondo to bring it up to the right surface height. Then primer and paint. I used a single stage PPG paint instead of clear. I didn't know how blending a clear would look with the Imron paint which is not clear coated. I took a piece of the fiberglass I cut out to the paint store and they used their computer system to match the color. [attachment=2249][attachment=2250][attachment=2251]
The final picture is of the finished product. [attachment=2252] If you remember, I said I installed the single unit low high HID. I didn't think a single unit would look right, so I found a pair of used 90 mm low beam Hellas on Fleabay for 50 bucks. They are installed for aesthetics right now. I may get energetic and wire them just to flash as courtesy for the truckers.
And the finish is a laugh at my expense. It's a lot of work to mask the entire front of the coach to prepare for painting. And it's a lot of trouble to paint. After I painted it, I could see a ripple in the fiberglass on both sides where the old met the new. I could see it or feel it until the surface was glossy. So, I sanded it all down, fixed the ripple, primered and painted again. It's the Entrekin way. Do it twice, or three times till you get it right.
Newell uses a 90 mm Hella sealed unit. You can source those from Rallylights.com. I decided to go whole hog and install the bixenon. Translated into English this means I used HID lighting for the low and high beam.
Step one was to cut out the out headlights and the recessed fiberglass that surrounded the lights. That is picture one. [attachment=2245] Pictures two is a shot of prefabbing some flexible fiberglass sheeting to give me something to start filling the hole.[attachment=2246] I simply put wax paper down on a smooth surface, wet some fiberglass cloth with resin, and waited for it to cure.
I needed some round tubes to act as the recesses for the round units. So I found appropriate sized pipe or tubing, waxed the outside of the pipe, and wrapped it with resin saturated cloth. When that cured I had fiberglass tubing to make the recesses for the lights and new round blinkers. [attachment=2247]
I have added a few pics that show building the layers of fiberglas in place to fill in the hole. By the way the fiberglass on the front cap is 3/4 inch thick in this section. That's a lot of fiberglass. Two days worth :-).[attachment=2248]
After the glass was almost flush with the rest of the surface, I used bondo to bring it up to the right surface height. Then primer and paint. I used a single stage PPG paint instead of clear. I didn't know how blending a clear would look with the Imron paint which is not clear coated. I took a piece of the fiberglass I cut out to the paint store and they used their computer system to match the color. [attachment=2249][attachment=2250][attachment=2251]
The final picture is of the finished product. [attachment=2252] If you remember, I said I installed the single unit low high HID. I didn't think a single unit would look right, so I found a pair of used 90 mm low beam Hellas on Fleabay for 50 bucks. They are installed for aesthetics right now. I may get energetic and wire them just to flash as courtesy for the truckers.
And the finish is a laugh at my expense. It's a lot of work to mask the entire front of the coach to prepare for painting. And it's a lot of trouble to paint. After I painted it, I could see a ripple in the fiberglass on both sides where the old met the new. I could see it or feel it until the surface was glossy. So, I sanded it all down, fixed the ripple, primered and painted again. It's the Entrekin way. Do it twice, or three times till you get it right.