Feeler: Clear Headlight Lenses, Please vote! Options

[KAOS]

** I'm not sure if this needs approval because its in the Exterior Styling area, but mods please let me know... thanks! **

So - I have been in talks with local companies (in Canada) that are willing to work with me to help create one of two clear lenses for our headlamps.

I've been researching two different ways;

Method #1: The poly injection method, which involves creating a polished steel mold for each headlight lens and is quite expensive, but would be a direct replacement for the glass, and sturdy as hell.

Example: http://www.youtube.com/watch?v=NedTUB7YQE0&NR=1

Method #2: The usual plexiglass/poly mold method, done in the past; however I have a different blueprint for how I'd like them molded so still very little customization would be needed (hopefully) to make them fit/seal properly. Pro's: definately more cost effective, and cons would be; there could be a ton of modifications to get them to work properly (MAYBE, depending on if my idea works) & they would take more time to make (high turnaround time).

I have a quote from the first project/idea, and its not "pretty" but I would prefer to go that route if possible because of the quality and the idea of having a direct replacement is very appealing to myself (having dealt with the clear lens molds from prior buys...)

I know what the previous clear lenses went for $$-wise, but in order to gauge what project I start, I need to know who's interested in what. I need to know the volume perspective to see if it will be worth while (and I'd get my invested money back) to go the first route... or if there's little to no interest for the clears, then I would pursue the molding method #2.

Post up with what you would prefer, and what you would be willing to spend on them.

PS - just a rough estimate; to make Method #1 a possibility, I would need to have at LEAST 200 units made... so yeah.

Summary:

1) Polycarbonate Injection Molding: MORE $$, DIRECT REPLACEMENT, GREAT QUALITY.

2) Poly/Lexan Heated Molding: LESS $$ than Injection Molding, NOT DIRECT REPLACEMENT (but possibly very close), still great quality, but long turn around time

PLEASE VOTE!

This post has been edited by KAOS: Oct 21, 2010 - 3:10 PM

[KAOS]

But for those of us who would like to have a customized retrofit, these lenses would be a no-brainer. I'd rather spend $500-600 on an entire retrofit project that I did myself, take pride in my work, and still be unique with the look of OEM, than spend ~$1000 for OEM projectors.

... mind you I do know a few of us who have been lucky getting the entire set for $500ish, but lets be honest, how often does that happen?

Either way, the lenses aren't for sale right now, and that price was just a rough estimate using the numbers given.

Obviously the more I make the better the price is going to be... but how could I ever get 300+ confirmed units? LoL.

I wouldn't spend that kind of money on OEM if I didn't have to. Yeah they would look good, but who's to say that someones custom retrofit wouldn't look BETTER/CLEANER...?

Anyways, I'll do some more research into the Thermoforming, and Pouring methods with different companies and get back to you guys. I haven't given up yet.