Templates for converting tail lamp pads to Lucas 542 - rectangular lamps

[Gumball]

If anyone is interested in converting their tail lamp pads from the large oval (for the two round lights per side) to the semi-rectangular shape of the Lucas 542 lamp, I'd be happy to provide my metal templates for shipping cost only. The only caveat is that you have to make them available to the next person who is interested.

These were a great help in reshaping the rear of my body. The first thing I did was glass over the holes that were pre-cut by FFR from the inside of the body. This was needed for two reasons: 1) the holes were right where the rectangular lamp mounting studs needed to go; and 2) to thicken the fiberglass significantly so that I could grind away a fair amount on the outside on the outside without burning a hole in the body.

PM me if interested, but post here so others know you beat them to it - anyone else who is interested, please follow the chain here and PM whoever has them down the road.

Fiberglass build-up after cutting out the center between the two FFR-cut holes:

http://i845.photobucket.com/albums/ab15/CCRsAC/FillingHoles3_zps8244d109.jpg (http://s845.photobucket.com/user/CCRsAC/media/FillingHoles3_zps8244d109.jpg.html)

View of the fiberglass build-up from the inside - be sure to add about 3/16" or 1/4" of material here before grinding on the outside:

http://i845.photobucket.com/albums/ab15/CCRsAC/FillingHoles4_zpse2ea376a.jpg (http://s845.photobucket.com/user/CCRsAC/media/FillingHoles4_zpse2ea376a.jpg.html)

Before and after with the template in place:

http://i845.photobucket.com/albums/ab15/CCRsAC/IMG_20130615_172648_zps26c42c05.jpg (http://s845.photobucket.com/user/CCRsAC/media/IMG_20130615_172648_zps26c42c05.jpg.html)
http://i845.photobucket.com/albums/ab15/CCRsAC/RecontouringPads4_zps9840c117.jpg (http://s845.photobucket.com/user/CCRsAC/media/RecontouringPads4_zps9840c117.jpg.html)

Final bodywork around the area to smooth the transition:

http://i845.photobucket.com/albums/ab15/CCRsAC/FinalSanding1_zpscc6f3e1c.jpg (http://s845.photobucket.com/user/CCRsAC/media/FinalSanding1_zpscc6f3e1c.jpg.html)

Once painted:

http://i845.photobucket.com/albums/ab15/CCRsAC/IMG_20140419_132151974_HDR_zps452d6456.jpg (http://s845.photobucket.com/user/CCRsAC/media/IMG_20140419_132151974_HDR_zps452d6456.jpg.html)

[DaleG]

Make a pair out of thin aluminum before shipping out?

[Gumball]

Make a pair out of thin aluminum before shipping out?

How about I trace them on some cardboard and make those available to whoever asks - say six copies or so? I can mail those in a simple envelope - no shipping charge.

[Gumball]

The beauty of the heavy steel ones, though, is that you can grind the body, using them as a guide. Also, you can build-up the filler right to them, then unbolt them and knock them out from behind, leaving just some flashing to work smooth.

If anyone opts for the paper templates, I highly recommend making a set out of thicker gauge metal for the actual work.

[aspbite]

PM sent for the cardboard version . Thanks

[carlewms]

Chris,

Thanks for the offer; PM sent.

As I recall these are single element lights? Did you convert them to two element or just leave as is?

Carl

[Gumball]

Chris,

Thanks for the offer; PM sent.

As I recall these are single element lights? Did you convert them to two element or just leave as is?

Carl

I made a pair of housings for the lamps, then ended-up converting those housings to actually hold the sockets from the four original lamps provided by FFR. I had to cut a little of the metal on the Lucas lamps to get this to work, but the result was great. I now have four running lamps and two function as brakes while the other two are the turn signals. This way, when I have a turn signal on, the two brake lamps stay fully lit!

The original box I made:

http://i845.photobucket.com/albums/ab15/CCRsAC/img_4133.jpg (http://s845.photobucket.com/user/CCRsAC/media/img_4133.jpg.html)

Here's the paper cut-out that I used as a pattern:

http://i845.photobucket.com/albums/ab15/CCRsAC/img_4132.jpg (http://s845.photobucket.com/user/CCRsAC/media/img_4132.jpg.html)

I then drilled two large holes in the back of each box to accept the modified sockets:

http://i845.photobucket.com/albums/ab15/CCRsAC/IMG_20140318_084543301_zps71ed8fea.jpg (http://s845.photobucket.com/user/CCRsAC/media/IMG_20140318_084543301_zps71ed8fea.jpg.html)

And added a separator to keep the light from one bulb from bleeding through to the other side:

http://i845.photobucket.com/albums/ab15/CCRsAC/IMG_20140318_083222362_zpsc34b9335.jpg (http://s845.photobucket.com/user/CCRsAC/media/IMG_20140318_083222362_zpsc34b9335.jpg.html)

And added the sockets:

http://i845.photobucket.com/albums/ab15/CCRsAC/IMG_20140316_155048396_zps99dd5a6b.jpg (http://s845.photobucket.com/user/CCRsAC/media/IMG_20140316_155048396_zps99dd5a6b.jpg.html)

The entire thing is held together by rivets and the edges are sealed using 3M non-silicon seam sealer.

[carlewms]

Chris,

Kool with a big K. Thanks, Carl

[cChrisM]

Never mind, just read it again. "View of the fiberglass build-up from the inside - be sure to add about 3/16" or 1/4" of material here before grinding on the outside:"

Thanks for this, Figure its not too hard to make a template from the rubber gasket onto some steel. Question, is the body think enough to grind off the material on the top and bottom. It seems like a lot of material needs to be removed. Did you reinforce with fiberglass on the back side of the body? Thanks

[Gumball]

Hey guys, sorry for the delay. I managed to finally pick-up some posterboard so that I could cut some paper templates and will be mailing those out to everyone who asked for a copy shortly.