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Is there a template available if I want to cut plexiglass for my recessed 1979 headlights? I will be returning to stock but that will be near last before paint. The current open design was full of debris when I got it and it did have some sort of cover at one point.
Chances of any template out there matching really well is thin
Get some tracing paper, tape it over top, use a straight edge where you can, freehand the corners, copy that to a piece of cardboard or better yet a piece of 1/8" panel-board and cut it out. sand to fit (make sure both sides actually fit, drill two large holes in the center or stick a loop of ducktape to it so you can pull it back out when it does drop in ) and when happy transfer it to some acrylic.
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So I found some light plastic and made a rough cut. Left is better than the right. Should be good enough to cut a pc of plexiglass. Add a bit of weather stripping too?
When tracing the right-side templare onto plexiglass....add a little extra to the top the corner of the plexiglass to fill in the missing area on your template.
try a bunch of cans, bowls, coffee cups. you will find something that is correct or close enough for the round corners to trace. you will probably need diff radius for several of the corners. curves in plexi are hard to do. cut off wheel works but melts it. jigsaw will want to crack it. band saw is best. there is also no saying the openings are original and not altered. so find that out before investing in OEM light bodies. 5-600 bucks and they don't fit will **** you off. and you need them easily removable. stuff will still get in from underneath and bulbs and wires fail.
Last edited by derekderek; Jan 5, 2022 at 10:39 AM.
Headlight covers
) and when happy transfer it to some acrylic.
