26R headlamp covers

[garyeanderson]

I have a kit of 26R headlamp covers that I bought from a friend 15 years ago, I was going to use them to loose a bit of weight up front on my S2. Well I haven't got around to it so they are still sitting in a bag. I was wondering if there was any sort of market in the U.S. I see Tony Thompson has covers and such but I haven't actually seen his covers or mounting plates.
My friend does a bit of Fiberglass work and has done covers for the Factory Five Daytona Coupe and has learned a bit about making them. If there was enough demand I was thinking about making up some new kits using the same 5 3/4 inch Hi/low lamps as in the kit I have. I don't have a clue on what it would cost so this is all preliminary leg work.
I don't know the weight savings as I havn't weighed either but I would guess it is probably be a net weight savings of 15 to 20 pounds. If you think that estimate is high, there are 2 fiberglass buckets, 2 glass lamps, 2 steel nests with trim rings, the vacuum canisters and springs and all of the associated vacuum lines and switch. So what do you all think?

Gary

p.s. - yes it probably cheaper to go electric but so what... its Winter here and water is freezing in the garage.

[ecamiel]

HI
I MIGHT BE INTERESTED. How much?

CONTACT ME OFF LIST

ERIC

203 792 0382

[email protected]

[garyeanderson]

I talked to my friend Thursday that has the experiance molding covers. He said about $300 a pair was what he was getting from Factory Five Racing for the Daytona Coupe lamp covers. This was a little more than I thought would be reasonable for an Elan owner to pay. The molds need a left and right, top and bottom so thats 4 pieces shaped out and glassed smothered and covered with felt or flocked cotton. The molds would need to be extended 3 or 4 inches on the perimeter of the actual part to make sure that the plastic's shrinkage doesn't telegraph back into the actual product. My costs would be close $500 kit (preliminary estimate) which seems out of line but thats what it looks like. Tony Thompson Racing has the covers for 85 GBP a pair and with all the other peices of the kit would add up to something over 200GBP so its in the ballpark, just not the ballpark I can get into. If I could get at least 10 orders it might work but that would be only just enough to cover the costs, maybe.

Some of the sites I looked at were

http://www.s-v-c.co.uk/lights_head.html

http://www.holden.co.uk/displayproducts ... +%2D+Parts

I don't know why S-V-C looks to be half of what Holden is charging, maybe quality or because the can. Shipping is an unknown but I do not think it will be minimal, I was thinking of getting the head lamp nests and the lamp harnesses from one of the above companies and I would source of duel filiment bulbs for a LHD car on this side of the pond.

I had two inquiries off list, one only wanted the covers only and the other wanted the kit I currently have. Therre doesnt seem to be enough interest to do much further work.

Gary

[cabc26b]

Sounds a bit much , TTR sells the covers for GPS 85/pr. I did the plexiglass/perspex on a sports racer using the drape-mold method, the head lamps and door glass were done in in my weber gas grill at about 200 degrees F. It took about 4 hours to make the aluminium forms for the head lamps. - once the grill is warm it takes about 1 beer to make em - including trimming and sandding the edges-

I used higher quality plastic from aircraft spruce for the windshield and doors. but remember using thinner sheets sourced from the HomeDepot for the headlamps ( my buckets were scavenged off XJ6's in a junkyard - even came with a trick cibie cat-eye lamp.)

[garyeanderson]

Hi George

Yes, Tony Thompson sells the covers for 85 GBP. Thats $170 plus shipping, customs, and other costs. To get the nests and wiring harnesses somewhere else and pay the shipping, get it all together and either hold inventory or ship to the end customer.
To have the covers made here would be nice to do as they seem to be the costly part of the kit. I asked my friend for a quote, he has enough work to keep himself busy. He wants to put some money in his pocket for a low production run. I thought 10 sets would be a minimum. There is not much there to cover the mold making time. I mentioned Tony's stuff in my second post. the basic kit ordered all through Tony Thompson is a little over 200 GBP plus shipping and customs or getting close to $500. Make the molds yourself and the price may fall into the aceptable price range.

Gary

The estimated guess/quote for $500 is better then to under estimate it at $300 and go over budget to $500 and pass the additional costs on.

[msd1107]

It may be possible for the headlight covers to be a DIY proposition. Lexan sheets are available from multiple sources (see links below) in different thicknesses and surface treatments. Rough cut, drape over form (old headlight?), soft form in oven (understanding significant other) or barbecue(!), cool and form to final shape with dremel.

It should be possible to use the existing wiring since +12 and ground are already there, hopefully with relays.

The headlights are not too heavy, but the trick is get a mounting kit with adjusters that are light weight. And use HID bulbs. A varity are available in different color temperatures and mountings.

By the way, what does this do to the headlight height above the pavement as to the various vehicle code requirements? Maybe we can fast talk our way out by claiming that is the way the car came. Or use quick adjustable height in case the ruler comes out.

And has anybody weighed the various components of a stock headlight setup and compared it to what the new setup would weigh? A 15/20 lb savings sounds darn attractive. The stock buckets are pretty light, and they have height adjusters.

http://www.fusiontechnology.com/headlightcovers.htm
http://www.grisdale.com/racing/bodies2.php
http://web.ncf.ca/ag136/windshield.htm
http://www.sr20forum.com/road-racing/12 ... hield.html
http://www.staginglight.com/editorials/pv7.html
http://www.up22.com/lexan.htm

David
1968 36/7988

[garyeanderson]

Well wrong again, I weighed up the original headlamp assemblies as I managed to lay my hands on most of the the parts. A grand total of 13 to 14 pounds for all of the stuff in the picture against nearly 5 pounds for the 26R kit that I posted the photo of last week. Total difference ends up 8 or 9 pounds off the very front of the Elan.