Housings for Lucas Rectangular Lights

[Gumball]

Here are a few pictures of the housings I made for my rectangular Lucas lights. I first made the cardboard template, then copied that onto thin aluminum sheet purchased at Ace Hardware. I drilled the corners to relieve stress, then cut out the shapes. I used a small Harbor Freight bending brake, my bench edge, and a 2x4 to make the bends, then riveted the corners together. The hole for the wires is 3/8" with a rubber grommet.

These were really easy to make, just a bit time consuming to get everything right. If you're interested in a copy of the template, PM me and I'll scan a copy and send it to you.

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)

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

Housing without sockets or divider.....

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

Rear view - gaps were sealed with clear 3M seam sealant......

http://i845.photobucket.com/albums/ab15/CCRsAC/img_4135.jpg (http://s845.photobucket.com/user/CCRsAC/media/img_4135.jpg.html)

[riptide motorsport]

Very nice craftsmanship!

[patpur]

Nice job, like to see them installed. I'm considering the same for my car.

[Fifty-Two]

Wow! Extremely well done!
Are you using the standard 1-bulb Lucas re-pops?

- John

[Gumball]

John - Yes, single bulb version from **********.

[3kcarbon]

Here is how to do it with dual bulbs... I didn't want to let the smoke out and it was easier for me to just go with it.

[AC Bill]

Really nice workmanship guys!:) I would really like to add those lights at some point.

Gumball, is this case mainly for protection from road debris? I could see the need if you were doing two sockets, like 3K did, but why is it needed for just the one socket set up, isn't the stock set up satisfactory as they come? Also, why not just add the two sockets at this point?

3K, Curious how the sockets are fastened to the case? Would you change bulbs (when required), by removing the sockets from the rear, or taking off the lens and accessing them that way? What sockets did you use for them, and where are they from?
I bet there would be a good market for those case's set up for the two light system. Plan on making anymore..?:)

Also, is the body simply sandwiched between the case and the lens, with only the lens seal used? If you wanted to make them weather resistant, I gather you would need to add a seal to the lip of the case where it touches the body from behind, or perhaps silicone them at that point..?

[Gumball]

Bill - The single lamp version of these lights that I bought from ********** have the bulb sticking straight-up behind the lens with no protection whatsoever (sort of looking like a wall sconce if you were to hold the face of the lens to a wall). In addition, the lens housing was wide open at the top and closed off at the bottom. So, my reasons for these housings were threefold: 1) To offer some weather and damage protection to the bulb; 2) Keep debris such as dirt and rocks from collecting in the bottom of the lens; and 3) serve as a reflector for the bulb - directing as much light from the single bulb as possible out through the lense. For the last purpose, I will use some polish on the inside of the housing before final installation.

As for mounting, my plan is to put a thin closed-cell foam strip around the flange, then sandwich the body between the lens/gasket on the outside and the housing on the inside. If you really want to make them weather resistant, you'd need to use some aluminum tape and/or high-temp sealer at the edges and corners, but make sure you leave a weep hole at the bottom for any moisture that gets in.

Finally, just a couple of additional tips:

1) Use .025 aluminum to make the bending easier and to allow the housings to conform to the shape of the inner body area where they will mount.
2) Mark the bend lines to ensure that you get crisp lines and make sure to punch or drill holes at all the corners to relieve stress and avoid cracking the material.

I'll try to post a better copy of the template as soon as I scan it - forgot to bring it to work today, so it'll be a day or so.

[MPTech]

great job!

just curious, is there any reason you couldn't rivet a divider in the middle for a 2 bulb setup, and could you run LEDs? (I heard someone now makes an LED that plugs directly in the standard bulb socket).

[3kcarbon]

Really nice workmanship guys!:)3K, Curious how the sockets are fastened to the case? Would you change bulbs (when required), by removing the sockets from the rear, or taking off the lens and accessing them that way? What sockets did you use for them, and where are they from?
I bet there would be a good market for those case's set up for the two light system. Plan on making anymore..?:)

Also, is the body simply sandwiched between the case and the lens, with only the lens seal used? If you wanted to make them weather resistant, I gather you would need to add a seal to the lip of the case where it touches the body from behind, or perhaps silicone them at that point..?

The socket are the snap in type like some license lights use, they came from NAPA but I would source them elsewhere. NAPA is over priced. The snapin type is easy, hit it with a proper sized hole saw and its ready. The snap contact acts as a ground. You are right to service the bulb you just pop it off and back in. The black rubber on the housing is on the outside and I made a silicone sheet gasket for the inside. You have to cut out the single bulb holder on the ********** lights to setup for dual bulbs and snap in sockets. There are ways to make the single bulb work but why do it? The harness is setup for duals and they are brighter and safer. A LED conversion from the start may be a good move as well.

[Gumball]

Here's todays TTT on an old how-to that I posted for making a housing for the Lucas rectangular tail lamps. Not sure what FFR is providing with those lights on the FIA / USRRC cars, but if no housings are included, this is a good upgrade for those cars - as well as for those of you modifying your Mk4 to use these lights.

As I completed the car, I did some upgrading to the lights - the original plan was to use the single bulb version... i.e., an original style lamp. But, based on some of the feedback in this thread, I decided to re-purpose the FFR-supplied sockets and install two bulbs in each housing. The top are brake lights and the bottoms are the turn signals. That allowed me to wire the tail lamps with ease using the Ron Francis harness, as well as gave me brighter rear lights, since the brakes stay on continuously rather than having one side blinking if I'm slowing and indicating a turn at the same time. But, this did require a separator in the housing, which is shown in the first picture (which is new for this thread).

As mentioned above, I still have a PDF of the template, so PM me if you're interested in a copy and I'll be happy to e-mail it to you.

Also - see here for info on modifying the pads on the rear of the body for these lights..... http://thefactoryfiveforum.com/showthread.php?7645-Chris-Bodywork-Thread-Mk3-1&highlight=chris%27+bodywork