how to build a head light pod / air scoop

Well i've started today but this could take a while so please bear with me on this build ..

Started by getting an old headlight ..
put it in the sink and filled the inside of the light with very hot water from the tap .
Then i boiled the kettle and stood headlight up and poured water over the joint between glass and plastic back and the glass needed very little help from me with a screw driver to split it apart ..




Once i removed the glass i had a good look at the unit and asked myself why when people build these scoops do they remove the mirrored lense and then spend time rebuilding the same basic shape to build the air directing scoop again !

I got my grinder out and cut through the plastic back and mirrored part  then stripped it all apart to clean up the cuts .



Re assembled the unit used my glue gun to hold the two parts together then set about making the two parts become one big part using fibre fill ..



This will line up perfectly with my custom air box that is currently being fed by my indicator duct




And thats pretty much all i've done so far .. but the basic shape is there .
Just more fibre fill then some body filler to smooth it all then paint ...

easy as that


i will update this as and when i do some more to it

Good start to the thread, i probably would of taken the less sensible route and smashed the glass off after the day ive had
Keep us updated

Great write up nice to see others going a how to

yep well wrote rob

i done one nd stuck it in the oven to get glss off, wouldnt have thought about boiling water which is a better idea tbh and it saves the other half moaning at ya lol

Abit more fibre fill

sand down the high spots and apply some filler


I'm still puzzled as to why everyone who makes these remove the mirrored part .
It makes for a perfect funnel

Looking good how much fibre glass does it take to fill the surround?

not alot really .... maybe half a small tin of fibre fill ....
If you wanted to make it lighter you could glue some plastic over the top of the hole and then just fill the gaps ...

Looking good so far ;-)

Sanded it down and had a good look over the pod thingy . at the back/inside there is a gap and it just doesn't look right .

Needed a little somthing
so got my soldering iron out and some black plastic and plastic welded some plastic in so it has more shape ..


sanded down and applied some primer to check for defects in my dodgy filler work


Few small holes filled and sanded and it's nearly ready for paint


Going well i think .

Looking smart im prefering the look to how many people do it as it prutudes further keeping the glass shape rather than just flat

Job done

Very smart rob that a job well done

Good work

Looking good!
Be good to see the grill in place aswell tho lol

Can't put grill on... Car is in bits... See my strip down build in members protects section

Rob, do you remove the mirrored part once you filled the gaps with the fibre fill?
Or leave it in place and just primer over it and then paint it?
Cheers

Leave the mirror part in mate check pics 1st page

Do you think expanding foam could be used to fill the void betwee the mirrored section and the casing? Then sand it back and give a skim of filler?

You could use expanding foam you would have to try form some kind of side to keep the shape maybe card or abit metal or tape drill a hole in it then push the expanding foam into it just do a little at a time though otherwise it will just go everywhere .

I would suggest you do it back far enough to put a skim of fibreglass as i would think filler ontop of the foam would crack .

Nomad, i was just going to use the foam to fill the gap between the casing and the mirrored part, so the shape will be there as im just going between the 2 parts. Ill use the foam from the back of the unit to take up all of the gap, then once its hardened sand it back to shape.
I did think about using the fibre galss, but though that once the foam had hardened, the filler would be ok to go stright on top. i might have a little try on some first.
Thanks

You could pop the glass off fill mirrored part with paper tight wrap a piece of cling film around the glass push the glass back on then use expanding foam from the back you should be able to pull the glass off as the cling film will stop the foam from sticking to the glass .

Did the photobucket issue get solved? Can't see the pics on this how to?

if use the photobucket fix plugin for firefox or chrome you can see them .

Is that just a case of viewing with Firefox?