Saturday, October 26, 2024

Fog Light Fabrication

 

So today has been an awesomely productive and creative day. I started off rolling the car out the garage and putting back in face first, to give me more room to work around the back end. I have started to fit and plan out my rear end lights and fog light which has took some fabrication and modifications of some lamp units for an epic result. I started today by fitting the rear stop/tail lights to the guards themselves. I still need to fabricate and fit the brackets to hold the mudguards to the car itself so this is now on my radar to get sorted soon. The rear guards have the mouldings to accommodate a range of different rear lights. I have opted for the same as on my Cobra the Lucas 692 units, which are lovely lamp units to look at and are a perfect fit on the mudguards. The Lucas 692 units are shared on many cars of the era and are even the standard rear light units on the Aston Martin DB5 so it is certainly good enough for me. 

Fitting the rear lights is fairly straightforward. Start off by determining the centre point for the light and then I cut a 30mm hole to take the light unit but leaving a little movement to seat the light square and even. I then had to drill two 5mm holes for the fixing bolts and these are just simply secured from behind. I might consider making a weather splash guard for the underside of the mudguard as the electric terminals will take a fair old bash from the elements here so, prevention is better than cure in my opinion. The second mudguard is exactly the same process as the first as these are symmetrical parts and are not handed offside and nearside. Last bit her was just to bolt each light into the mudguards and rest on the rear wheel, waiting for the fabrication of the brackets.

So next up is an idea from the depth of my brain. I want to create a custom rear fog light that also incorporates the rear number plate light however it needs to all look on trend with the other rear light units and more importantly practical. I had an older Lucas 692 unit without a reflector so my idea is fairly simple, I intend to remove the centre section that holds the bulb and that should allow the bulb holder of the front unit to fit through. This will create a double back mount as such with a reflector on the front which will be used as a fog light. Then with some tactical cutting and fitting of a led bulb of the back unit will allow white light only to shine down to illuminate the number plate and the fog light will work independently without any light crossover. 






The removal of the rear centre section was fairly easy, it’s not going to be used as such so I just set about it with a hacksaw and cutting it away slowly to create the centre hole for the front light unit to fit through. I opened the hole up slightly with my dremel tool and as you can see pictured here it will fits together fairy nicely. The next step was to create the opening on the lower section for the light of the white led bulb to shine down onto the number plate. This I have just drilled a 6mm hole either side of the centre line and then opened the hole up with a reaming tool in the dremel again. 

So here you can see how I have created the holes on the bottom edge for the light. I intend to cut some clear Perspex or acrlic to make some protection against water ingress but I’ll have to find something suitable later on as I don’t have anything to hand currently. The two units are simply held together with two long bolts that pass through outer light and will clamp the back light plate between the body tub and front light. The front fog lense is held on with the original fixings so it can easily be removed to replace the bulb if needed. The number plate led will also be accessible to be replaced however this will require removal of the whole thing from the body. 
I have temporarily wired in an led and passed the wires through the centre hole so I can make sure my idea is going to work so next up was to mark and cut a hole in the rear of the body. A 30mm hole for the centre spigot with two 6mm holes for the fixing bolts either side.

I’m really really pleased with how this has turned out, I love seeing an idea through to the final result which creates something truly unique and yet looks completely normal and original to the vehicle. I still have a fair amount of fine tuning to do still but overall you can grasp what I’m trying to achieve as an end result. With everything mocked up and my number plate masking taped onto the body the whole thing is working perfectly and looks flipping awesome! I’m going to also now make a number plate bracket that clamps between the body and fog light housing which will be a nice solid secure fixing point for the number plate. So lots of little snagging jobs to sort now before I can conclude this little section finished but I’m exceptionally happy with the result… and most people won’t give it a second thought when they see it.

Lastly for this update I’ll share this picture of the car on the drive…. I must admit I’m really liking the big grill opening with the style of the car. Despite still under construction my Jag mk2 grill similar to Paul’s car, I’m going to have to decide what a I want and make some final decisions soon. But overall the whole thing is looking bloody fantastic… can’t wait to go for a drive. 


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