Hello there! Today we will show you the way in which the glasses for our optics were made, as well as the process of creating and chromium coating of headlights. Subscribe to the telegram channel. Let`s go!


Glass of the headlight

So, the process of creating optics can be divided into the creation of housing, installation of electrics and glazing. We have shown earlier the process of manufacturing the housing.

Today we will make glass. Here we have a finished glass of the headlight.

It seems to be nothing special in it, because it looks like ordinary bent plastic. But we spent the whole month making it.

We made glass on a vacuum forming machine. This machine was made by our hands as well. But we will present it later. Now I want to show you the process of creation the master model for our glass.

Master model

First we took the headlight body, installed it on the car and affixed it with the sealing foam.

Then it was cut, puttied and polished so that the surface repeated the shape of the car body.

Then the component part was removed from the car and we continued our works with it, having settled it on a rigid base.

Next, we lowered all sides of our piece part at a right angle, having previously made a margin of 2 millimeters on each side so that there was a gap when gluing the glass and the housing with a sealant.

Then we polished and grounded it. We could try to vacuumize it, but since it was based on foam, and it was very soft, the vacuum machine could simply crush it.

Therefore, we need to took the matrix from it, and to make a solid die mould of the matrix.

So, we took the matrix and made a die mould of it.

Then we returned to the machine.

Material choosing

It was necessary to determine what material to use for forming the glass. We chose the polycarbonate of a thickness of 3 mm.

We didn’t use plexiglass because it was fragile and very easily scratched. Polycarbonate is about 60 times stronger than plexiglass.

Next, we install the polycarbonate into the clamping frame of the vacuum machine.

We put such a frame on a sheet from above and clamp our plastic with the help of bolts.

Then we lift the frame up and turn on the heater. We use 2 radiant heaters for that.

Then we install the die mould into the working field of the vacuum machine.

After that we wait for the material to heat up and become elastic.

So, we warmed up the plastic and it became soft.

It even slacked a little from below.

Turning on vacuum cleaners

Now we turn on vacuum cleaners and lower the frame on the form.

The edges are pushed with a squeegee.

Now we wait a little until the plastic cools. Then we raise it and get the part out of it.

We specially made such a height for the die mould, because when we form a plastic of such thickness (somewhere about a centimeter), the plastic fits tightly to the part, and then it stretches and we are not able to stretch it completely.

But we do not need this, because we cut off the glass just about a centimeter in order to put it on the headlight.

Pull it out

So, the plastic is cold now.

We take the frame to pieces and pull it out of the vacuum machine.

We get such a work piece.

Now we have to cut it around the edges with an indent of about 1 centimeter and attach it to the headlight.

Result of our efforts

After cutting the edges, we get such glass.

It is the moment when we can install it on the headlight and see the result of our efforts.

The body of the headlight itself should be polished and painted. After that, we install the glass, glue it on the sealant and the headlight will be assembled.

It will look really cool!

Tail optics

We made glass for the tail optics in the same way. We also prepared a matrix, made a die mould of it, and formed the glass itself.

We have already mated this glass, and now I will tell you why.

Generally, the tail-lights glasses are of red color. We could use basically red polycarbonate. As you can see, there is a transparent strip on the original Gallardo tail-lights. In this strip there is a turn signal and back-up lamp.

Therefore, we had to take exactly the transparent glass and tone it into red, leaving this transparent strip.    

I’ll show you now the way in which we are going to do that. We made the housings of the tail-lights.

We produced them using the same technology as for the headlights. The process of making headlights is available here.

We also printed a tail-light on a 3D printer. We took the matrix from it and made a cast.

In order to designate the borders of the strip, which we need to leave unpainted, we apply glass on the work piece of the tail-light. The spots where the turn signal and back-up lamp should be located are glued with contour tape.

Pasting the glass with contour tape, we turn it over and put the same strip, but on the reverse side of the glass.

Now we can remove the tape from the front side.

We check the accuracy of the borders once again, by applying glass to the tail-light.

Covering with color

Then we cover it with a colored varnish. In order for the varnish to not get on the front side of the glass, we glue it over with adhesive tape.

We take the car two-component varnish and red dye.

Then we add there literally 1 ml of paint and mix it.

After we take the spray gun, pour our varnish in and apply it in several layers on the part with intermediate drying of somewhere 10-15 minutes.

So, we have tinted the glass, after which we carry it to the drying cabinet.

Now we will start chroming the housing. We have a tail-light housing prepared for metallization. We have grounded and varnished it.


Lamborghini inscription

Also, today we should metallize the Lamborghini inscription. The inscription itself was printed on a 3D printer.

We could of course buy the original inscription, but such a label costs about 20 thousand rubles. While we spent about 500 rubles on making it.

For metallization, we need this set of chemistry. Its price is 1500 rubles ($22). You can buy it and other materials here.

The solutions were mixed. Now we can proceed to metallization.

We have caused the activator and washed it. This is the time to apply the silver solutions.

Here we have chromized the inscription.

Next, we apply an adhesive primer on it and varnish it. After that, the varnish dries and it can already be installed on the car body.

Metallization of the tail-light

Now we proceed to the metallization of the tail-light. We apply the same scheme.

After the tail-light body has been chromized, we also varnish it and let it dry. Then we install the diodes here.

Diodes installing

We have already installed boards with diodes into this tail-lights housing.

As you can see on the original tail-lights, the Gallardo has reflectors located from above.

We took a breakdown triangle and sawed one side of it in half, ground the edges and installed it into the tail-light.

Let’s now estimate the glass and see how it will look.

So, the varnish is dry. Now we put it on.

As soon as we set the glass, the tail-light immediately starts playing. It looks almost like a real one.

I can’t even believe that it was done entirely with our own hands.

How diodes work

And now let’s see how the diodes work.

How does the back run work?

Now let’s check the turn signal.

Now the tail lamps.

When do our tail lamps turn on? When we click on the stop, it should glow brighter.

That’s all for today.

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Bye!

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