Making a new headlamp cowl

[timbrass]

My headlamp cowls were completely rotten so I had to make replacements





I used the one that was more or less intact and wrapped it in clingfilm and then made a plaster cast using plaster of Paris soaked cloth



I then used that mould (covered again in clingfilm) to make a glass cloth and 2 part epoxy copy








I then drilled holes to match the original rusted metal one. You can adjust the up/down left/right


The original lamps were sealed beam, but I replaced with UK ones that have replaceable bulbs


Now legal in the UK! The headlamp on a 2001 International is identical to that used on a Daihatsu Fourtrak or Mitsubishi L300 Van (so UK dipped lamps are available on eBay)

[headinthetrees]

Nice job. And think of the weight savings going to those uber fiberglass enclosures! ;p

[somewhereinusa]

Well done

[bansil]

sweet..okay very sweet

[HolyBus]

Fantastic job! My left side view mirror casing is half rotted away. If I had half you talent, I would build new casings for both sides.
You may have a great niche business idea. Do you do fiber glassing full time?

[timbrass]

I have used glass cloth and epoxy whilst restoring boats (Punts on the Thames) but I'm no expert! It was actually quite easy to do if you have a good original to make the plaster mould from. The key tips are wear disposable gloves at all times, weigh the 2 parts of epoxy to ensure correct ratio and mix for several minutes (use a watch!).