Hello everybody! In this episode I will tell you how we made the headlights. But first, by tradition, subscribe to the telegram channel. 🙂

3D model for printing

I asked my friend to create a 3D model of the headlights.

When he did it, we printed it with the help of a 3D printer.

Due to the fact that the headlights were not small, we printed them in parts. When all the pieces of the headlights were ready, we glued them together and got an integral part.

Parts of the headlights

When we glued the parts of the headlights, we began to refine them, since their shape was not perfect, because it was impossible to take the hood bend line into account when modeling the headlights, that’s why they had to be refined with the help of putty paste.

Glued headlight

So that´s how the glued headlight looks like. But here it is not just glued, it is already finished, polished, covered with “primer” and varnish.

Of course, from the inside, at the places of gluing, it looks not very beautiful. On the back side of the part you can see printing and gluing marks.

In fact, having printed the headlights, we could just install them in the car and use them, since they were made of ABS plastic, which is very strong.

But, since we are creating the car for everyday use, and anything can happen on the road, for example, an accident, or something else, every time we would have to print the headlight again and again, then glue it making the surface ideal, but that won´t work at all.

We decided to remove the matrices from these half-finished parts. As you can see, the headlight itself has a very complex shape, that is, it´s almost impossible to remove the fiberglass matrix from it, that´s why we began to think how this could be done.

Matrix preparation

My friend Dima told me that in order to remove the matrix from a complex form, it is possible to use molding silicone.

So we bought this type of silicone. Silicone itself looks like this.

Having bought all the necessary materials, we needed to proceed to taking a cast. To do this, we had to determine the position of the half-finished part.

We decided to take the cast by insert molding. We had to place the headlight in the horizontal position on its upper plane to do this.

At the edges of the headlight, we needed to make a formwork. I will show you how we made it using another headlight.

Formwork

We made the formwork in the following way: we placed the headlight horizontally, then we covered it with foam from all sides. We cut off the foam at the edges (about a centimeter on each side).

Then we covered it with the aluminum tape, and lowered everything to the base of the tabletop. After that we needed to make flanging in order to pour the silicone in.

We made this kind of thing.

It is put on the half-finished part of our headlight.

There appeared a half-centimeter gap between them, and the top has to be filled with silicone.

Then it’s necessary to wait for 12 hours before it becomes dry. When it becomes dry, we need to take it out of mold.

Making cast

Then we get this kind of silicone matrix. So, how to take a cast? You need to take a silicone form and pour liquid polyurethane plastic into it.

But since our matrix is ​​bent greatly, we need to place it on a hard base and make this type of flanging so that the form does not lose its geometric shape.

This is how we should put the form in our flanging; the main thing is for it to fit tightly and not to bend.

Stirring plastic

Having prepared the form to filling, we need to start stirring plastic.

Then we need to take plastic and stir it with the ratio of ten to six. 100 grams of plastic, 6 parts.

It is very important to mix these two components thoroughly, otherwise the plastic may not harden.

Pouring

After stirring plastic, we need to pour it into the mold.

When the plastic is poured into the mold, roll it all over the surface, like dough in a frying pan, when you are making pancakes.

We need to do this very carefully so that the plastic does not spill over the borders of our matrix.

We need to make about four or five fillings in order to increase the thickness of the plastic, otherwise the mold will be very thin, and when we get the part from the matrix, it will just break.

For taking a cast, we use the American heat resistant plastic because when the headlight shines, it heats up.

Casting of the headlamp takes about 15 minutes. You also need to wait another 20 minutes for the plastic to harden and the part could be taken out of the matrix.

So it takes about half an hour to make one headlight body.

Take out the plastic

When the plastic hardens, we should take it out of the matrix. First of all we should get the matrix itself, well, try to do it.

So first of all we should start from the edges separating the silicone from the plastic.

Then we should carefully take the headlight out of the matrix.

Last step of work

That’s it! Here we have the headlights body.

When we got the body out of the matrix, we needed to modify it a little bit cutting the formwork we initially made and finishing the surface. When we do it, the headlight will look like this.

Diodes installed

We have already installed bi-xenon lens, turning light, and steps with diodes in this headlight body.

Steps are made of the transparent plastic and printed on a 3D printer.

Sidelight

For the headlight body, we made a sidelight, to which we have already welded the mounting brackets for attaching them to the car.

With the help of the matrix, you can make about 5 sets of headlights a day.

These headlights will be of the same quality and shape.

Now we have to paint the headlight, install electrics and glass.

We will show you the process of making glass in the next episode.

Also we will show you the process of creating and chrome-plating of rear lights, so subscribe to our telegram channel and check for the updates.

See you!

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