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Old 12-08-2015, 09:56 AM   #1
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Lens cover materials ideas

I need to replace two of these types of lens covers (The plastic see-though-ish covers that cover the bulbs).
I tried making them from 2x4 light panels, but they keep breaking at different spots of building, so not a great idea. Any ideas? Thanks in advance...
Oh, two of them are in FLAWLESS shape, but I need two more and they don't need to match OEM exact, or even close.
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Old 12-08-2015, 11:54 AM   #2
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A flexible plastic, like polystyrene might work. It is available in white or clear. I'm just not sure how translucent the white is. Another option would be to pick up some large hardback cotton drum shades from a lighting store and cut them up into the size you need. This is what I'm talking about:
White Cotton Drum Cylinder Shade 8x8x11 (Spider) - #00107 | LampsPlus.com

Not sure it's stiff enough to hold the shape of the curve you need, but it might be worth looking at. You might even find some at a thrift store for a few bucks.
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Old 12-08-2015, 12:16 PM   #3
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Try, Shoji fiberglass screen.

Shoji Screen White Fiberglass Fabric by the Yard. Thin non-flammable fiberglass fabric (14 point) used for room dividers. Supplier. Shojii, Soji.
Or
http://www.tapplastics.com/product/p...shoji_plastics

Hope that works for you.

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Old 12-08-2015, 12:23 PM   #4
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Cool! That looks like it would be ideal.
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Old 12-08-2015, 01:26 PM   #5
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It needs to be a stiffer type of material, something like 1/16" plexiglass. I can use a heat gun to make the bend.
Heavy cloth-ish materials won't stay true at the bottom, particularly as on the road IMO...
Any more ideas? THANKS!!!
What have others done in the past?
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Old 12-08-2015, 01:37 PM   #6
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A few months ago someone posted a detailed thread here with pictures of his solution. He created a mold from one of his remaining good lenses. Then he mixed up plastic resin and made new lenses.

I don't know if his lenses are the same ones you need....maybe you could borrow his mold, or get him to make a few for you.

Do some more searching here on airforums.
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Old 12-08-2015, 01:57 PM   #7
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Any local plastics/plexiglass shopS can help you. If you go with plexi look for sign white as it diffuses the light nicely.
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Old 12-08-2015, 07:00 PM   #8
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Plastic

You can make your own plastic parts from brake lights to tools. Tap Plastics is just one of many companies that sell plastic molding equipment and the formula you will need to make a part like yours.
You can also weld Plastics. One Option is the Poly Welder Pro 200 Watt Plastic Repair Kit.
There is numerous companies that sell hobbyist mold and plastics making kits. They are very affordable.
There are also several companies that sell welders. The aforementioned welding is on Amazon for $130.00.
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Old 12-08-2015, 07:49 PM   #9
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I had pretty good luck forming 1/16 lexan from lowes to 90 deg bends. Loosely clamp one edge in wooden blocks and have form ready (cardboard/wood/pvc pipe). Heat with 1200 watt heat gun (harbor freight) until edge closest to clamped edge is limp. Bend. Work your way up the plastic. Hmm. Fit light cotton cloth over as filter? I know plastic fab will work.
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Old 12-08-2015, 09:57 PM   #10
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Have you tried Lexan? A source is Aircraft Spruce. They have it in all sorts of thicknesses.
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