khguan's DIY Gallery
DIY Custom Fiberglass Eyelids
1st December 2007
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Hi again, it's been sometime I didn't post new stuff here. Been bz with work n stuff. Thanx for all who stayed tuned to my gallery postings. :)

This time is the 1st time I mess with resin n fiberglass works. Well for the 1st attempt, I chose something small which is easier to fabricate and for practice. Here I have done two sets of fiberglass eyelids which is quite sucessful. Coming up next will be a custom "face-plate" for extending my subwoofer enclosure to fit longer subwoofers. Hehehe....
First n foremost, cover the entire headlight with masking tape.
First n foremost, cover the entire headlight with masking tape.
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Then cover the bumper as well with garbage bag. Just in case the resin drip down.
Then cover the bumper as well with garbage bag. Just in case the resin drip down.
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Draft the desired shape of the eyelids with pencil, rub off with eraser if alteration is needed.
Draft the desired shape of the eyelids with pencil, rub off with eraser if alteration is needed.
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Now draw the outline of the entire eyelid as a guide for the fiberglassing process.
Now draw the outline of the entire eyelid as a guide for the fiberglassing process.
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Check for potential leak areas, and it is ready for laying fiberglass.
Check for potential leak areas, and it is ready for laying fiberglass.
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Mix the resin with recommended amount of hardener in a small cup. Here I used a small mineral bottle cut into half n a 1
Mix the resin with recommended amount of hardener in a small cup. Here I used a small mineral bottle cut into half n a 1" paint brush.
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Apply a layer of resin on the guided area 1st, then apply a layer of fiberglass sheet on it. Apply resin to wet the fiberglass sheet to stick on.
Apply a layer of resin on the guided area 1st, then apply a layer of fiberglass sheet on it. Apply resin to wet the fiberglass sheet to stick on.
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Start on the other headlight and then apply 2nd layer of fiberglass on the first headlight. Apply enough resin and make sure no air trapped in between the fiberglass sheets.
Start on the other headlight and then apply 2nd layer of fiberglass on the first headlight. Apply enough resin and make sure no air trapped in between the fiberglass sheets.
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Push out air bubbles with the brush.
Push out air bubbles with the brush.
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Apply another layer (3 layers in total) of fiberglass and leave them to dry. This will take about 1-2 hours depending on how much hardener used on the resin.
Apply another layer (3 layers in total) of fiberglass and leave them to dry. This will take about 1-2 hours depending on how much hardener used on the resin.
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One thing to note is to lay the fiberglass slightly more than the guided area so that we can trim the edges later.
One thing to note is to lay the fiberglass slightly more than the guided area so that we can trim the edges later.
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Remove the hardened eyelids carefully and trim the edges with a cutting disc.
Remove the hardened eyelids carefully and trim the edges with a cutting disc.
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Using a grinding disc (paper type), by hands, sand the edges and the surface until both pieces are identical/symmetrical.
Using a grinding disc (paper type), by hands, sand the edges and the surface until both pieces are identical/symmetrical.
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Apply putty on the eyelids to cover the holes on the fiberglass eyelids. The left one is already sanded smooth with the grinding disc by hand. You can use a coarse sand paper too (100 grit).
Apply putty on the eyelids to cover the holes on the fiberglass eyelids. The left one is already sanded smooth with the grinding disc by hand. You can use a coarse sand paper too (100 grit).
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When the surface is smooth enough to the eye, now we use 600 grit sand paper with water for smoother finishing.
When the surface is smooth enough to the eye, now we use 600 grit sand paper with water for smoother finishing.
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Dry the eyelids thoroughly and spray a layer of paint.
Dry the eyelids thoroughly and spray a layer of paint.
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Tiny holes spotted. This time apply smooth putty to cover all the tiny holes n uneven surfaces. Once the putty dry, repeat the smooth sanding with water.
Tiny holes spotted. This time apply smooth putty to cover all the tiny holes n uneven surfaces. Once the putty dry, repeat the smooth sanding with water.
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Spray desired paint for a few layers, the other surface spray black to prevent light shining through the eyelid material. Spray clear coat for glossy finishing.
Spray desired paint for a few layers, the other surface spray black to prevent light shining through the eyelid material. Spray clear coat for glossy finishing.
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Done!! Stick the eyelids onto the headlights with double sided tape.
Done!! Stick the eyelids onto the headlights with double sided tape.
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Right side eyelid.
Right side eyelid.
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Left side eyelid
Left side eyelid
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Before I made those eyelids, heres the 1st version of eyelids I experimented with, which is now on my colleague's car.
Before I made those eyelids, heres the 1st version of eyelids I experimented with, which is now on my colleague's car.
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1st prototype right
1st prototype right
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1st prototype left
1st prototype left
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