[94SubieSVX]

Originally Posted by b3lha

The best way to do this is to find somebody with a vacuum forming machine.

It holds the lexan in a frame, heats it up, pulls it down over the mould and sucks out all the air for a perfect fit.

http://www.technologystudent.com/equip1/vacform1.htm

I wish I would have the money to be able to use a vacuum forming machine. The whole reason I'm trying this is so it will be a whole lot cheaper than the small car lenses. Also, I don't think many people would want to buy these, so unless there's about 20 people or so it wouldn't be worth it.

Originally Posted by superru

we have a vac-form machine here at my work. next couple weeks i'll try to make a mold of the head lights. but wouldn't forming over the stock light make a negitive mold that is 1/8" bigger (all the way around) than the stock light. then cutting the stock light the new mold wouldn't fit. so you would have to (inside the new neg mold) whatever the thickness of the material your using, line the inside with that. then when you pull the new mold of the "smaller" one, it will fit the stock housing perfect! did i loose anyone?
let me know if i've missed something.

That makes sense but I'm not going to make one single mold. I'll be using the "frame method" to make each clear headlight.