How to make lens covers for the aftermarket/replica Mazdaspeed GTC front bumpers. Keep in mind that this process can also be used on the OEM version. For starters the supplies needed would be.

1. 12x27" piece of 1/8" clear plexiglass (aka PG). You should be able to find this at any specialized window/glass store.

2. Can of black spray paint.

3. Portable jigsaw w/fine tooth blade. This blade will keep the plexiglass from chipping.

4. Several sheets of 8.5x11" paper either taped together so it’s large enough to be used as the initial temple. And darker construction paper for the final templet.

5. Scissors

6. Drill with drill bit for small screws.

7. Small flathead screws and nuts.

8. The kitchen oven.

9. Large flat baking pan. DO NOT use the black non stick ones. They absorb too much heat and will make the surface the PG will be laying on hotter than it should be.

10. Pencil

11. Tape

12. Both combo lights for the bumper.

13. Socks or mittens

First understand that the bumper will need to be off the vehicle. Why? Well the plexiglass is going to be heated in the oven. When the plexiglass is removed from the open, you will have about 20 seconds before the PG starts to harden again. Therefore running out to the garage or the street were your car is parked isn’t going to give you much time to mold the PG to the bumper.

 

First take your sheets of paper and some tape and tape them together. Makes sure that the taped paper is large enough to completely cover over the lens section of the bumper. Also make sure you have one of the combo lights installed in the bumper(will explain why later). Place the taped paper over the lens section of the bumper and using your fingers, press along the outline of the lens section. This will put a crease in the paper so that when it’s removed, you will have a general outline of the lens section. Now take your scissors and cut around that outline. This will be your initial templet. Place this templet over the lens section again and check for gaps and inconsistencies and trim as needed. This is where leaving the combo lights installed helps because the lights naturally protrude outward basically giving the pager a place to rest. This will make your templet more accurate. Basically what your trying to do is make the paper fit like it’s the actual PG cover and the combo lights will keep the paper true.

 

Once you finally have the initial templet cut perfect, transfer that templet onto the darker construction paper and cut it out. This is your final templet. Once again place the templet over the lens section to make sure everything is perfect with fitment. Due to the thickness of construction paper, this will give you more of an indication that your templet is right.

 

With the temple finalized, transfer it onto the plexiglass with your pencil. Use the jigsaw and cut along the line and perfect as possible. If your really talented with the jigsaw, you shouldn’t have to sand the edges at all.

Now preheat the oven to 375 degrees. The cook setting should be on broil so the heat comes from the top). Place the baking sheet in the center section of the oven so it preheats as well. While the oven is preheating, bring the bumper to the kitchen near the oven. Take the protective lining off both sides of the PG. Place the PG in the oven for 5 minuets. Grab your socks or mittens to protect your hands. After 5 minuets are up, remove the PG and quicky place it on the bumper. You will notice how soft the PG has become and it will virtually mold into shape. Keep in mind that you will have less than 30 seconds to make sure that the PG molds to the overall contours of the bumper. You will also have to place even amounts of pressure over the entire PG to make sure everything if nice an flat. Use a rubbing method. NOTE: do not hold pressure in the same section. The softened PG will show indentions from your fingers if you do this. Don’t worry if you mess up the first time. The PG can easily be placed back in the oven to be re-softened again (but only for a few times). Once you have the PG molded correctly, drill holes through the PG and bumper so it can be fastened with the screws and nuts. Counter sink the screws for a flush fit. There, now you have lens covers for your GTC bumper.

 

I used smoked PG for this illustration so it could be seen better. The real covers that you make should be clear. Once you have them formed you then use the black paint to paint around the inside outer edges of the cover. Only the center light section of the cover is clear, the rest is blackened out just like the real MS covers.

Also this process could possibly be used in making your own lens covers for the sleek head lights. I haven't tried to make those yet.

And to those of you who intend to make and sell these, good luck. Not every aftermarket bumper is molded the same. early last year I tried to fit a pair of mine on another local Rx7 and they didn't fit (huge gaps). So I guess there are differant after market manufacturers for these bumpers.

Lastly you will need to make a second pattern for the other side as it is slightly molded differant. Simply flipping the pattern over will not yield good results for the other side. If you have the OEM bumper, you could get away with filpping the pattern because of it's better quality.

 

very good writeup!!! i wish i knew this before sending mine out to get copied!!! LOL

 

Thx for the complement!

Oh yea these should only cost you about 20 bucks to make.

 

that looks awesome. good job man

 

Nice work.

 

That's handling business! Great jarb.

 

it never would have cross my mind to use hot water, like molding a mouth piece for sports, and not that damn heat gun I been trying to use. thank alot T-von

 

Great writeup and really nice job.

 

>>it never would have cross my mind to use hot water

did i miss somthing? i didnt read anything about water up there?

 

well you do need nearly boil hot water to heat up the pelixglass(pg), when the pg gets hot its really make it easy to bend. that what i meant, like if your a football player or a boxer you heat up your mouth protector so it fits the form of your teeths or mouth. because i was using a heat gun, but after gettin hot then cold a few time it would crack

 

o' yeah cool web page damian

 

thanks :-)

 

ouch! wouldn't that burn?

awsome write up btw

 

Just suggestion to make the mold easier to use. Make the regular paper cutout like this doc says. Then do some paper-mache kinda template to lay the plastc over after you take it out of the oven. That way you don't have to run the plastic out to the car before it cools.

Great write up!

 

no, u know those culligan water thingys? well the hot water from that is fine. soak it in one of those til its soft and shove it in ur mouth and bit hard. take it out and itll be shaped to ur teeth.

 

very nice job, keep it up

 

nice write up. Im going to try this with the earlier style mazdaspeed bumper.

 

NICE write up! saburo, lets go get that bumper and try to make the lense.

 

its kind of a pain in the *** to get the template right, other then that it isnt that difficult

 

its kind of a pain in the *** to get the template right, other then that it isnt that difficult

 

Yep getting the templet right took me a while too. Do you have any pics of yours?