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How to create clear lens with reflector detail

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To replace headlamp covers found on many military models
How to create clear lens with reflector detail
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English version    19:54    6.01.2020
Sometimes there is a need to replace military headlamp covers with a "glass" lens. Here a lens was created for a 1/35 Vulcan Zundapp K800 motorcycle.



Start with a scrap of clear sprue. Clean up the end with a file and sandpaper.



Heat end over flame, being careful not to scorch the plastic



Quickly press the heated end onto a row of staples. Make sure to hold the sprue perpendicular to the staples.



A slight improvement to the methods is to use a drill bit size gauge on top of the row of staples to form the round shape of the lens when the clear sprue is pressed down


While attached to the sprue, file and sand the edge to the correct diameter. Can be placed in a drill and rotated to get a good result.



Remove the lens from the sprue with a razor saw.



File the rough edge (opposite the imprinted pattern) to the desired thickness.



Clean the file marks with fine sandpaper (1000 grit). Bevel the edge for a more rounded lens profile.



Polish with compound - e.g. Novus No. 2. Finished!
     

      

    


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