radioflyer97
04-10-2010, 06:12 AM
Custom Door reflectors.
If you have access to, or know someone who has a waterjet or laser cutter, you can do some REALLY cool stuff with your door reflectors. You can also do this with a scroll saw if you have enough patience.
Parts needed:
(4) 3-LED pods
Spray paint (black , and another the same color as the LEDs)
¼” clear acrylic (about 6”x6”)
¼” smoked acrylic (about 12”x6”)
(4) bolt, washer/locking nut sets
10’ 22ga speaker wire
(2) 2-conductor quick connect (optional)
Tools needed:
Dremel with cutoff wheel or ripsaw
Drill with drillbits
Power sander (belt style recommended)
Band saw (recommended)
Butane Torch (recommended)
Solder gun (recommended)
Step 1: remove the door reflector and use the Dremel to remove the front from the back of the plastic. Sand down the front surface of the Design your image based on the available area without cutting into the tabs. If you’re using a non-computerized cutter, sketch this image on the back of the plastic with a sharpie. Once you’re satisfied with the cutout, spray paint the front black.
Step 2: cut the image
Step 3: Use the plastic reflector mount as a stencil to trace onto your smoked acrylic. This is your new “lens”. Cut these out then use your power sander to bevel the edges to about 320grit. From that point, hand sand to 400 grit. You can use your pocket torch to really smooth out the beveling to a glass-smooth transparent surface.
Step 4: Cut your clear Acrylic to support both the LED pods and screw mounts (shown below) Spray paint the back of this piece the same color as the LEDs. Line up the main lens, reflector mount and the clear acrylic and drill your mounting holes.
Finished parts:
http://i27.photobucket.com/albums/c200/radioflyer1986/2010%20persnal%20projects/IMG_0105.jpg
Step 5: Assemble the parts to look like this:
http://i27.photobucket.com/albums/c200/radioflyer1986/2010%20persnal%20projects/IMG_0103.jpg
Testing:
Off:
http://i27.photobucket.com/albums/c200/radioflyer1986/2010%20persnal%20projects/IMG_0106.jpg
On:
http://i27.photobucket.com/albums/c200/radioflyer1986/2010%20persnal%20projects/IMG_0107.jpg
Step 6: remove your door panel. Tap into the foot well lights with your 22ga speaker wire and run this wire through the door. (I suggest using zip ties or duct tape to make sure the wire doesn’t interfere with window operation) Replace the door panel allowing the wires you just ran to hang outside the reflector hole
Step 7: using either your quick connects, or direct solder, connect the LED leads on the new reflector to the wire you just ran. Verify the polarity is correct by unlocking your car. The reflector should light. Install the reflector and you’re finished!!
Mounted: (on)
http://i27.photobucket.com/albums/c200/radioflyer1986/2010%20persnal%20projects/IMG_0101.jpg
http://i27.photobucket.com/albums/c200/radioflyer1986/2010%20persnal%20projects/IMG_0102.jpg
If you have access to, or know someone who has a waterjet or laser cutter, you can do some REALLY cool stuff with your door reflectors. You can also do this with a scroll saw if you have enough patience.
Parts needed:
(4) 3-LED pods
Spray paint (black , and another the same color as the LEDs)
¼” clear acrylic (about 6”x6”)
¼” smoked acrylic (about 12”x6”)
(4) bolt, washer/locking nut sets
10’ 22ga speaker wire
(2) 2-conductor quick connect (optional)
Tools needed:
Dremel with cutoff wheel or ripsaw
Drill with drillbits
Power sander (belt style recommended)
Band saw (recommended)
Butane Torch (recommended)
Solder gun (recommended)
Step 1: remove the door reflector and use the Dremel to remove the front from the back of the plastic. Sand down the front surface of the Design your image based on the available area without cutting into the tabs. If you’re using a non-computerized cutter, sketch this image on the back of the plastic with a sharpie. Once you’re satisfied with the cutout, spray paint the front black.
Step 2: cut the image
Step 3: Use the plastic reflector mount as a stencil to trace onto your smoked acrylic. This is your new “lens”. Cut these out then use your power sander to bevel the edges to about 320grit. From that point, hand sand to 400 grit. You can use your pocket torch to really smooth out the beveling to a glass-smooth transparent surface.
Step 4: Cut your clear Acrylic to support both the LED pods and screw mounts (shown below) Spray paint the back of this piece the same color as the LEDs. Line up the main lens, reflector mount and the clear acrylic and drill your mounting holes.
Finished parts:
http://i27.photobucket.com/albums/c200/radioflyer1986/2010%20persnal%20projects/IMG_0105.jpg
Step 5: Assemble the parts to look like this:
http://i27.photobucket.com/albums/c200/radioflyer1986/2010%20persnal%20projects/IMG_0103.jpg
Testing:
Off:
http://i27.photobucket.com/albums/c200/radioflyer1986/2010%20persnal%20projects/IMG_0106.jpg
On:
http://i27.photobucket.com/albums/c200/radioflyer1986/2010%20persnal%20projects/IMG_0107.jpg
Step 6: remove your door panel. Tap into the foot well lights with your 22ga speaker wire and run this wire through the door. (I suggest using zip ties or duct tape to make sure the wire doesn’t interfere with window operation) Replace the door panel allowing the wires you just ran to hang outside the reflector hole
Step 7: using either your quick connects, or direct solder, connect the LED leads on the new reflector to the wire you just ran. Verify the polarity is correct by unlocking your car. The reflector should light. Install the reflector and you’re finished!!
Mounted: (on)
http://i27.photobucket.com/albums/c200/radioflyer1986/2010%20persnal%20projects/IMG_0101.jpg
http://i27.photobucket.com/albums/c200/radioflyer1986/2010%20persnal%20projects/IMG_0102.jpg