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Hi everyone,
After several recent junkyard trips, I've come to the conclusion good replacement lenses for the Vanden Plas ( US market ) rear reading lights are unobtainium ! The B-pillar lenses are likewise impossible to find since the plastic seems to dissolve away leaving only crumbs ( possibly some type of acetate ? ). Even the good sets I've found have stress lines that reappear after sanding & polishing them.
My best original set ! Normal junkyard condition ! Ready to self-destruct ! Toasted !
I'm currently experimenting with making replacements from casting resin. The reading lights look pretty good, the latest test batch I cast using a pressure pot which eliminated almost all visible bubbles. I didn't do the interior recess on the originals because of the extra work needed for a two part mold as well as reducing the strength of the finished part. I think the originals were done that way to reduce the amount of plastic needed and possibly speed up production ( faster cooling / de-mold ).
3 originals on left with defects / dimples ! 2 on right with bubbles in resin. Originals, first set with bubbles, last set no bubbles ! Originals with recessed interior & casting defects in threads ! Solid new casting ( with bubbles )
Is anyone here interested in getting any ? I'm not sure about pricing etc yet, just trying to see if there is enough demand to make a small run of extras. The current test pieces are made with an epoxy resin ( easy to use, low odor ) but I plan to make my final ones from a higher temp resistance Urethane resin that's actually DOT & FAA approved for lenses ( it make fumes and requires heat curing ).
Two part B-pillar molds, time to test cast a set !
I'll post pictures of the B-pillars once I'm cast some test articles.
The ones that came in the car Shattered when I merely touched them to replace the spent bulbs, scattering Shards all over the front seats! The shards were sharp enough to cut the leather seats, and of course, worked their way deep into the creases. I was able to vacuum them away but it took Great care not to cause damage to the leather.
I would be interested in a pair, certainly, even though I was able to find a good pair in a newly arrived Wrecking Yard example. As you mention, they nearly crumble from just looking at them. To preserve what I have, I have installed Jose's mod to keep the door switches from engaging, but there are times it would be Really nice to have a light when I open the door.
(';')
I don't have those VDP "C" post lights because my XJ is not a VDP model but I will be interested in 4 or 6 of the clear round lenses too. I have one of those chromed lamps without the lens.
My "B" post lenses are still fine but I don't know how long before they dissolve.
Good job reproducing these parts.
Looks good, I'll be watching this. The 2 part B pillar mold in silicone is well done, it will be interesting to see the part. Usually the bubbles are prevented by "de-airing" the mixed resin or silicone in a vacuum pot prior to pouring, is that what you mean by a pressure pot?
I used to have a small vacuum chamber used for this sort of thing. The cavity tool was vented and placed in the chamber with a hose to the outside for the molding compound. When vacuum was pulled in the chamber, a valve was opened to introduce the compound and it is sucked into the cavity tool. Once the compound exits the vent, the valve is closed and the compound is left to cure. The whole process is performed under vacuum so entrained air (bubbles) is prevented.
On the condition of factory lenses, I think it's likely the heat rather than age that kills them. I found a pretty good original set (clear, no cracks or discoloration) a while back and changed to a LED bulb to avoid the heat build up and hopefully the need to replace in my lifetime. Also quite bright. I have yet to find an interior light lens in any car that stands up to the heat generated by incandescent bulbs without any air circulation.
You may be able to continue to use the epoxy resin if a LED bulb is used because heat is no longer a problem. 3D printing is also a possibility for making things like this. There are materials that print clear, but for a lens would require quite a lot of sanding and polishing to get something usable in my experience.
Hi everyone,
After several recent junkyard trips, I've come to the conclusion good replacement lenses for the Vanden Plas ( US market ) rear reading lights are unobtainium ! The B-pillar lenses are likewise impossible to find since the plastic seems to dissolve away leaving only crumbs ( possibly some type of acetate ? ). Even the good sets I've found have stress lines that reappear after sanding & polishing them.
My best original set ! Normal junkyard condition ! Ready to self-destruct ! Toasted !
I'm currently experimenting with making replacements from casting resin. The reading lights look pretty good, the latest test batch I cast using a pressure pot which eliminated almost all visible bubbles. I didn't do the interior recess on the originals because of the extra work needed for a two part mold as well as reducing the strength of the finished part. I think the originals were done that way to reduce the amount of plastic needed and possibly speed up production ( faster cooling / de-mold ).
3 originals on left with defects / dimples ! 2 on right with bubbles in resin. Originals, first set with bubbles, last set no bubbles ! Originals with recessed interior & casting defects in threads ! Solid new casting ( with bubbles )
Is anyone here interested in getting any ? I'm not sure about pricing etc yet, just trying to see if there is enough demand to make a small run of extras. The current test pieces are made with an epoxy resin ( easy to use, low odor ) but I plan to make my final ones from a higher temp resistance Urethane resin that's actually DOT & FAA approved for lenses ( it make fumes and requires heat curing ).
Two part B-pillar molds, time to test cast a set !
I'll post pictures of the B-pillars once I'm cast some test articles.
Cheers,
Brian
Brian,
Is a fantastic idea to cast the lense
Let us know how it goes.
Hi everyone,
finally did my first test cast of the B-pillar lenses using the low VOC epoxy. I tilted the mold so the epoxy could go in the bottom ( white straw ) and flow out the air vent ( red straw ). The mixture pooled in the funnel I had attached to the straw, so I used my hand vac pump to suck it out until it appeared in the vent straw. I was sure there were going to be huge gaps or bubbles in the finished part but it actually worked ! I can't use the harder & higher temp resistant urethane which makes fumes until the arctic blast leaves again since I don't have a heated shop to work in ( working inside and plan to open a window while working under the range hood on high ). The epoxy looks good but I'm sure it would soften and flex enough to pop loose during the summer since the lenses snap on the base. The other possible issue is that the new ones might be too clear, letting the lamp base be seen through the plastic, I'll just have to check that when I make the first ones with the urethane. It can be tinted etc so I might try some "frosted" ones etc.
Could everyone in the USA who's interested in getting a B-pillar set check your parts pile for any bad ones that have good trim parts, I'd appreciate it. That would save me having to make those parts separately. Overseas members, don't worry right now, I'll try to source some extras to attach to your lenses. Please don't try to cut the rivets with a dremel etc, they will get hot and melt the trim piece -- ask how I know !
Those lenses look pretty good. Well done. I don't think you need to be concerned about the black plastic bit on the bottom. I can print those from black ABS and make them available or you can do the lens only and let it be a replacement for assemblies in which the lens is toast but the base if fine. I have a spare assembly in good condition (not for sale, its a spare for my car) that I can work with to model the base. I'll do that this week and I can print one and send it to you to try it out. I think you can send a private message in this forum to get me an address if you are interested.
I'm quite impressed with your result. Very nice indeed.
Here is the CAD model of the B pillar light base. I'm printing a few as we speak. There will be a right and left, the first ones will be the right hand side. If the dimensions are correct I'll do the mirror image.
So here is the printed base. kudzu, if you want one to trial fit, send me an address and I'll send one.
The lights in my 86 Series 3 have a black base like this. However I have seen them with a chromed base as well. I don't know when the cutoff to black took place. I have some chrome metallic paint coming for another project so I'll see what these look like with that coating product.
Hi Niles,
The new trim parts look nice ! I'll send you a pm.
I think the Series 1 or 2 cars had chromed trim while the 3's had black or beige / doeskin-deerskin ( whatever it is ! ) to match the upper B-pillar trim color. It might have been only the 86 & 87 non-VDP cars that had non-black B-pillars, research project anyone ?
I'll try to make some parts next week using the urethane resin once the temperature gets back into the 50's so I can open my windows if needed to air out my house. It also has to be baked in an oven after setting up in the pressure pot to fully cure it which might be smelly as well !
Hi everyone,
been busy with work & helping parents so not much time for this project. I finally got a good set of the B pillar lenses using the urethane after two failures while doing the heat curing of the cast parts ! The first time the toaster oven's temp control ran away and the second time they came out looking melted because of possible moisture issues ( had washed the molds to remove dust and air dried but maybe not good enough ). After following the instructions exactly I got it to work: baking the molds for a couple hours at 212 degrees F, then pouring resin followed by 4 hours back in the oven at 212 to heat cure.
I'm vacuum degassing the resin after mixing before pouring but NOT pressure casting them ( like the failed attempts ) since I can't heat and pressurize them at the same time. Because the interior is faceted and somewhat satin finish anyway, I don't think any tiny bubbles will be visible anyway. The Vanden Plas reading lenses will need the pressure so I'm testing a different method for them.
As you can see, my production line is going to be quite slow since I need to be home or close by to monitor the baking for 6 hours per set ! Or until I make another set of molds then 2 pairs in one days work, really rolling then !
To clarify who wants B pillar & VP reading light lenses please check below to make sure I have it right, thanks !
B-pillar Light & Vanden Plas Reading light lenses
The shards were sharp enough to cut the leather seats, and of course, worked their way deep into the creases. I was able to vacuum them away but it took Great care not to cause damage to the leather.
