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If you have experience with fiberglass this is an easy project, if not follow the directions on the resin container and my instructions below and you shouldn’t have that much trouble.

Materials needed
Fiberglass and resin mix
Fiberglass matting
Painters tape
Car wax or release agent
Rubber gloves
Sanding / filing tools
Paint brushes

The first step is to wrap your headlight, or headlight/cornerlight assembly in painters tape. It’s a good idea to use to layers to avoid bleed through ruining you headlights. It’s also a good idea to draw the eyelid shape you desire on the headlight with a magic marker.

The next step is to cover the painters tape with a release agent. You can use cooking spray, car wax, vaseline, or whatever will stop the resin from embedding itself in the tape. I personally like car wax, or vaseline. Now is also a good time to cut the fiberglass matting into manageble sizes and mix up the resin/ harndner mix.

Now your ready to make a mess. Coat the marked out area with your resin mix. Then stick the fiberglass matting on to the resin and force the resin into the mating using a paint brush so it’s all a uniform color. Make sure that the entire marked out area is covered with matting and as flat and bubble free as possible. Its ok to go outside the lines, because it will be cut later, your actually better off if you go outside them because it will give you a more even thickness when you cut it. When it’s all covered leave it to dry.

You now have your first layer of fiberglass complete. I like to sand it down to get some of the big bumps out and even it out a bit. I use a 6″ disc sander, but a sanding block will work as well. Try not to go to crazy because you could ruin the light if you sand through the tape.

Once again sand the eyelid down. At this time I sanded it alot more so the eyelids were flattened on the face and were closer to the final shape. it should be a pretty even thickness all the way through the whole eyelid at least up to your marker lines.

now that the basic shape is there, I like to put a nice gloss coat of resin over the lids. To do this you will just use the resin hardner mix, no additional matting will be added at this time. when you brush it on make sure to cover the entire marked area and lay it on smooth and even, try not to leave any runs. This will help eliminate some of the final sanding if done right. Notice in the picture how smooth and shiney it is, that’s how you can tell it right. Before it was bumpy after the matting steps.

Now the eyelid form is complete and it’s time to remove them from the headlight. This step is most important to have patience with. Carefully pry the eyelids from the headlight, try not to force it, if it doesn’t want to come off then go to another section and work from there. When it’s all free it’s time for shaping. Magically the marker will be transfered to your eyelid mold when you remove it from the headlight. I like to cut the lids short of the mark so I can final sand it to the desired shape. Its easer to trim more than to put back the what was over trimmed.

last I like to use a block sander or a belt sander to get the final shape, it makes it easier to get a straight line with out waves or bumps.

to get the final paint worthy finish, I like to tape up the headlight assembly again and tape the eyelid to it to sand it. It’s less likely to get broken from aggressive sanding with the headlight as support.

Finished pictures coming soon