I'm creating some updated headlights for the crossfire with morimoto parts. I 3D scan the housing so that I can do some alterations to it and then print a new housing while still using the factory lenses. So far it's coming out pretty cool.

 

I wish you well on your endeavours.

 

Thanks 😁

 

Is there a way of printing a new clear front lens? If so then we can actually build new headlights.

 

You need clarity, so stretch forming a clear sheet would be a good method. Forcing a mirror finished core into a hot sheet of plastic using heat and vacuum etc. would be one way. Opting for a flat lens with sides bonded to the back face would be the simplest.

 

I should have been more respectful to the original poster @MAYAman and complimented his fine work and research. We need more stuff done like this to keep our cars on the road considering it's such a niche market. So thanks and the work your doing is very nice.

This might be the best method of construction for small shop makers. Heat and vacuum form the font lens as a curved plane. Print the support form that interfaces the lens to the back housing. Glue those two parts together. Then that assembly can clip to the housing.

 

That is a great idea, the lens does not to have to be too thick. Polycarbonate (Lexan) is an ideal lens material and what they are now I believe.

 

FYI I'm experimenting with different methods (vacuum form, molds, heat molds, etc. Once I'm done with the mounts and housing I'll move to the lenses.