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Old 01-04-2015, 01:26 PM   #1
Skoolie
 
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Join Date: Sep 2014
Location: Henley-on-Thames, United Kingdom of Great Britain and Northern Ireland
Posts: 114
Year: 2002
Coachwork: Bluebird
Chassis: International
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Making a new headlamp cowl

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)
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Old 01-04-2015, 03:24 PM   #2
Skoolie
 
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Nice job. And think of the weight savings going to those uber fiberglass enclosures! ;p
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Old 01-04-2015, 06:03 PM   #3
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Well done
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Old 01-05-2015, 05:20 PM   #4
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sweet..okay very sweet
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Old 01-05-2015, 09:00 PM   #5
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Join Date: Dec 2014
Location: Florida
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Year: 1988
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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?
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Old 01-06-2015, 10:46 AM   #6
Skoolie
 
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Join Date: Sep 2014
Location: Henley-on-Thames, United Kingdom of Great Britain and Northern Ireland
Posts: 114
Year: 2002
Coachwork: Bluebird
Chassis: International
Engine: DT466e
Rated Cap: 29
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!).
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